7.2 risk assessment and disaster management plan...

Proposed expansion of Multi-Purpose Plant/Fluorospeciality Plant (3000 TPA to 6000 TPA); Installation of new generation Refrigerants & Refrigerant

Blends Plant (90,000 TPA) and Change in Product Mix of Chloromethanes and HFC134a At Village & P.O.-Jhiwana, Tehsil-Tijara, District-Alwar (Rajasthan)

Final EIA / EMP Report

7.2 RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN

7.2.1 Risk Assessment & Damage Control

The risks associated with the chemical industry are commensurate with their rapid growth and

development. Apart from their utility, chemicals have their own inherent properties and hazards.

Some of them can be flammable, explosive, toxic or corrosive etc. The whole lifecycle of a chemical

should be considered when assessing its dangers and benefits. The chemical industries have

potential to cause disasters whose consequences are not only limited to the workers and

management, but also to the society and environment at large. The various chemical disasters that

have taken place world - wide both in developed and developing countries stand a proof to the

consequences. The disasters in chemical industries are generally due to fire, explosion and toxic

release.

Activities requiring assessment of risk due to occurrence of most probable instances of hazard and

accident are both onsite and off-site.

On site

� Emission/spillage etc. from storage & handling

� Exposure to fugitive dust, noise, and other emissions

� Housekeeping practices requiring contact with solid and liquid wastes

Off-site

� Exposure to pollutants released from on site/ storage/related activities

� Contamination due to accidental releases or normal release in combination with natural

hazard

� Deposition of toxic pollutants in vegetation / other sinks and possible sudden releases due to

accidental occurrences

Some of the important points considered to avoid/reduce any kind of hazard in the industry are:

� Design and Pre-modification review: Proper layout like location of plant in upwind side of

tank farm , fire station away from process area, process area far from public road and right

material selection can reduce severe damages to the work and outside environment

� Chemical Risk Assessment: Compatibility, storage, fire protection, toxicity, hazard index

rating, fire and explosion hazards

� Process Safety Management: HAZOP, FTA, F&E Index calculation, reliability assessment of

process equipment, incorporating safety trips and interlocks, scrubbing system, etc. before

effecting major process changes, proper Management of Change procedure (MoC), etc.

� Electrical Safety: Hazardous area classification , protection against static electricity , proper

maintenance of specialized equipment like switchgears, MCC Rooms

� Safety Audits: Periodical assessment of safety procedures and practices, performance of

safety systems and gadgets along with follow up measures.

� Emergency Planning: Comprehensive risk analysis indicating the impact of consequences and

specific written down and practiced emergency procedures along with suitable facilities.

� Training: Safety induction and periodical refresher training for the regular employees and

contract workmen shall be carried out.




7.2.2 Risk Analysis Methodologies

Risk assessment often requires the synthesis of risk profiles, which represent the probability

distribution of total annual loss due to a certain set of events or activities. These assessments

usually involve estimation of losses for several sub-classifications of the overall process and

synthesis of the results into an aggregate risk profile.

Some of the Main risk assessment methods adopted in Chemical Industries are:

� Standard Conformance And Performance Evaluation (SCOPE)

� Hazard and operability study (HAZOP), and

� Fault Tree Analysis (FTA)

7.2.2.1 Standard Conformance and Performance Evaluation (SCOPE)

SCOPE would evaluate the existing measures / system based on applicable national / international

standards. A few SCOPE reviews for chemical manufacturing plants are:

� SCOPE-FP (Fire Protection)

Indian Standards

� IS 2189 - Standard for automatic fire detection and alarm system

� IS 2190 - Code of practice for selection, installation and maintenance of first aid fire

extinguishers

� IS 3844 - Code of practice for installation and maintenance of internal fire hydrants and

hose reels

� IS 6382 - Carbon dioxide fire extinguishing system - fixed, design and installation

TAC Standard

Tariff Advisory Committee recommendations on hydrant and sprinkler system for fire

protection.

Oil Industry Safety Directorate

� OISD 117 - Fire Protection Facilities for Petroleum Depots and Terminals

� OISD 142 - Inspection of fire fighting equipment and systems

� OISD 158 - Recommended Practices on Storage and Handling of Bulk Liquefied

Petroleum Gas

� SCOPE - OHS (Occupational Health and Safety)

� IS 14489 Code of Practice for Occupational Safety & Health Audit

� NFPA 101 Life Safety Code

� SCOPE-ER (Electrical Risk)

� Hazardous Area Classification (base standard: IS 5572)

� Selection of Electrical Equipment for Hazardous Areas (base standard: IS 5571)

� Lightning Protection (base document: IS: 2309 /NFPA 780 /BS 6651)

� NFPA 70 B Recommended Practice for Electrical Equipment Maintenance

� NFPA 70 E Standard for Electrical Safety in Employee Work places




7.2.2.2 Hazard and operability study (HAZOP Study)

The HAZOP study is a systematic technique of identifying hazards of operability problems of a

process and lists all possible deviations from normal operating condition and how they might occur.

The consequences of the process are assessed and the means available to detect and correct the

deviations are examined. Thus, within the entire process all “credible” deviations that could lead to

hazardous events or operability problems are identified.

7.2.2.3 Fault Tree Analysis (FTA)

FTA is primarily a means of analyzing non-identifiable hazards. Hazards of top events (the ultimate

happening that is to be avoided) are first identified by other techniques such as HAZOP. Then all

combinations of individual failures that can lead to that hazardous event show the logical format of

the fault tree. Estimating the individual probabilities and then using the appropriate arithmetical

expressions can calculate the top event frequency.

The following Hazards are identified at the Plant.

a) Fire in Electric Panels, Oil room, Diesel storage building.

b) Spillage of chemical and wastes.

There are several other risk assessment technologies, the same are classified as follows:

1. PROCESS SAFETY MANAGEMENT

� Event Tree Analysis (ETA)

� Primary Hazard Analysis (PHA) using Dow Index

� Risk Assessment (with risk ranking technique)

2. ELECTRICAL RISK ASSESSMENT

� Review of Hazardous Area Classification

� Lightning Protection Risk Assessment

� Identification & Control of Electro-Static Hazards

� Review of electrical Preventive Maintenance System

3. FIRE RISK ASSESSMENT

� Identification & assessment of fire risks during operations in receipt, storage, transfer and

handling of chemicals (raw materials and finished products)

� Identification & control of ignition sources in areas where flammable chemicals are stored /

handled / transferred

� Review of chemical compatibility in storage areas and to suggest appropriate fire loss

control measures

� Review of fire detection measures adopted in the plant & to suggest suitable improvement

measures

� Review of the various active (fire hydrant, sprinkler, portable fire extinguishers) and passive

fire protection requirements for chemical storage and handling areas and to suggest

improvements as necessary

� Review of contractor safety awareness (chemical spill, fire fighting, emergency

communication, knowledge of plant hazards & safety regulations) and to recommend

suitable improvement measures to enhance contractor safety




� Review of safety awareness and safety training requirements

� (Training identification and efficacy) of plant employees with respect to hazards present in

the plant.

“The consequence, likelihood and exposure of each hazard are arrived using a systematic approach

and will help to determine the relative importance of hazard and focus on significant risks”.

7.2.3 Risk Analysis & Emergency Plan

Figure 7.1 PHOTOGRAPHS SHOWING RISK ANALYSIS & EMERGENCY PLAN




Figure 7.2 PHOTOGRAPHS SHOWING FIRE HYDRANT SYSTEM & FIRE EXTINGUISHERS




7.2.4 EHS Management at CB Unit of M/S SRF Limited

� With TQM as its guiding philosophy, Bhiwadi site is improving its organizational effectiveness

and changing the fundamental way in which it looks at things. Bhiwadi site is also working

towards developing and improving managerial, technical & marketing skills of its people.

� Bhiwadi site has regional marketing offices at Mumbai, Chennai, Kolkata and New Delhi with

its Central Marketing Office (CMO) at Guragon.

� An Environmental, Occupational Health and Safety Management system cell exists headed

by AVP (EHS) which monitors the legal compliance and the environmental parameters in the

plant premises.

� There exists a sophisticated laboratory equipped with state of the art equipment such as Gas

Chromatographs, Spectrophotometers, Stack monitor, High Volume samplers, BOD and COD

Analyzers, Ionometers, pH meter etc. for monitoring various environmental par

� There is a well equipped occupational health center with round the clock trained first aider.

There is an ambulance available with oxygen facility.

� The effluents from various plants are analyzed for the constituents. At ETP, the effluents are

treated and part of the treated water is recycled to the plant for scrubbing of acid emissions,

if any. Rest of the treated water is used for horticulture activity.

� The gaseous emissions from the plant are scrubbed using water as a scrubbing media and

some of the resultant dilute acid effluent is sent back to the plant. Balance is treated at the

effluent treatment plant, where it is converted into useful product & reuse.

� The Cell checks and prevents the unsafe practice and condition in the plant areas through

daily, weekly, monthly & Quarterly audit of the plant. It ensures the procurement of

appropriate quality of PPEs and its use. It identifies the EHS related training.

� This Cell monitors the implementation and compliance to applicable EHS legislations. It

conducts investigation of accidents, Near Miss & Non-Conformance and suggests corrective

and preventive measures.

� It coordinates with timely conduct of EHS Committee meetings.

� At Bhiwadi site there are three tier EHS committees to discuss and resolve safety &

environment related problems / issues.

� There are 7 nos. Area EHS Committees practically covering all plant areas / activities.

� There is Statutory EHS Committee to discuss/ monitor statutory related issues.

� There is Apex EHS Committee Management Review Committee) to review the Safety

Performance of all committees as well as overall safety performance of plant.

� SRF Bhiwadi site organizes Mock drills once in a quarter to check the preparedness, based on

On-site Emergency Plan.

� At the time of joining every factory based regular employee and Contract worker is required

to undergo compulsory safety training. Refresher Safety training is organized at regular

basis. In addition to this need based training are also organized.




� SRF Bhiwadi site also organizes EHS Promotional activities on the eve of National Safety Day,

Fire safety day & World Environment day etc. SRF is committed for a cleaner, greener & safer

environment and continual improvements are carried out in various areas.

� CB Unit is proving its organizational effectiveness and changing the fundamental way in

which it looks at things. CB is also working towards developing and improving managerial,

technical & marketing skills of its people to compete successfully.

7.2.5 On Site Emergency

An emergency which may cause serious injuries, loss of life, extensive damage to property or

environment or serious disruption inside the plant, or the events that are commonly having serious

implications like major fire hazards, causing serious burns to personnel resulting in collapse or

structures or release or toxic substances in the environment.

BASIC OBJECTIVES OF EMERGENCY PREPAREDNESS PLAN

1. To spell out overall action plan for effective mitigation of any emergency.

2. Reduce risk to human health & life both within the works boundary and outside.

3. Minimize damage to property both within and outside the boundary

4. Liaison effectively with the Government Authorities/ Public/ Press to avoid panic situation

and public disorder.

5. To protect the environment

The overall objective of the plan is:

To localize the emergency and if possible eliminate it

Emergency plan covers following:

1. Assignment of specific responsibilities to all categories of personnel.

2. Effective communication of the nature of emergency to authorities within the organization.

3. Contain & control the emergency

4. Rescue and treatment of the affected person (s)

5. Safeguard people in and outside the works.

6. Institutionalization of works emergency action.

7. Maintenance of orderly public relation. Provide information to media & government

agencies.

8. Identify causalities notify their relatives and render necessary help to them.

9. Termination of Emergency.

10. Rehabilitate area affected

11. Appraisal of Local Hospitals/Nursing Homes/Doctors on specific emergency treatment

required for persons affected, relevant to SRF.

12. Preserve record/ equipment for subsequent enquiry.




EFFECTIVENESS OF EMERGENCY RESPONSE PLAN:

The following essential things should be taken care-off for the effective implementation of the

Emergency Preparedness Plan.

1. Periodic review and Updating of the plan.

2. Periodic rehearsal of the plan by way of Mock Drills.

3. Review and the strengthening of the Resources needed.

4. Training of the site personnel in handling emergency equipment like the use of various Fire-

Fighting Equipments, Use of Chemical suits with BA sets.

5. Rescue and treatment of the affected person (s)

6. Safeguard people in and outside the works.

7. Maintenance of orderly public relation. Provide information to media & government

agencies.

8. Identify causalities notify their relatives and render necessary help to them.

9. Termination of Emergency.

10. Rehabilitate area affected

11. Appraisal of Local Hospitals/Nursing Homes/Doctors on specific emergency treatment

required for persons affected, relevant to SRF.

12. Preserve record/ equipment for subsequent enquiry.

The Onsite Emergency Plan is divided in 3 Parts:

� Pre Emergency Activities

� Activities During Emergency

� Post Emergency Activities

The onsite emergency / Disaster control plan out lays the detailed sequence of steps to be followed

by plant personnel in case such an eventuality occurs in chemical Business of SRF Limited either in

day or night time due to collapse of buildings/structures, leakage or fire of any hazardous chemical,

viz. leakage of CI2, AHF, HCl, H2S04, fire in Methanol tank etc. It details out of the management

system that would work at the time and defines the location, responsibilities and step by step

studies of Emergency Officers. It also forms the basis of Mock-Drills to be carried out at least once a

quarter to prepare and improve upon the state of preparedness to tackle any emergency as well as

update the onsite Emergency Plan as when necessary.

The onsite emergency / Disaster Control Plan will be reviewed at least once in a year.

7.2.5.1 EMERGENCY CONTROL CENTRE

The fundamental need of a Emergency Plan is to establish two control centers, one at the affected

site (Incident Control Centre) and the other one reasonably away from the affected site

(Emergency Control Centre).

There are two Emergency Control Centres decided on the basis of prevailing wind direction.

1. At Main Gate ( New office of Security Head )

2. At HFC Control Room




7.2.5.1.1 UTILIZATION OF EMERGENCY CONTROL CENTER (ECC)

This centre is utilized for receiving and assessing information and approval.

This is headed by Chief Co-ordinator along with Admin, Co-ordinator & Safety co-ordinator. This

centre is equipped with:-

� Plan of the factory Layout

� Internal/ External Telephone Nos.

� Walkie – Talkie

� Emergency Phone with list of phone nos.( hot line)

� Site-Master Plan

� List of important persons at site, head office, and Govt. authorities outside along with their

names and telephone numbers.

� List of equipment / PPEs/ other facilities available at ECC

� A copy of On Site Emergency plan

� Jeep with PA system (at ECC-1)

� MSDS

� Fire Extinguishers

� Fire Fighting Accessories

� List of First Aiders

� List of Emergency Response Team

� Fire Proximity Suit (1 No.) at each ECC

� Self contained breathing apparatus (2 Nos.)

� Chemical Suit (1 No.) at each ECC

7.2.5.1.2 Incident Control Centre

Location of Incident control centre/ rooms:

Five Nos. control rooms provided with sizes:

� CMS Control Room - First Floor, Size -12 Meter x 11.5 Meter

� RG/HF Control Room - First Floor, Size - 12 Meter x 6.5 Meter

� CPP Control Room -First Floor, Size- 9.0 Meter X 7.5 Meter

� HFC-134a Control Room-First Floor, Size 6.0 Meter 15 Meter

� SCB -P2 Control Room, Ground Floor, Size- 7.0 Meter X 6.0 Meter

Locations of the Control rooms are absolutely safe and properly located to have a better

operational control of the plant, even in emergency situation.

Incident Control rooms have been provided with:

� Internal/ External Telephone Nos.,

� Plan of the Area

� STD phones

� Emergency Phone with list of phone nos.( hot line)

� Walkie -Talkies




� PA system and Emergency Siren switches

� Copy of On-Site Emergency Plan

� MSDS

� List of equipment / PPEs/ other facilities available at ECC.

� Fire extinguishers, Fire Hose, Nozzles, Fire Box Key Self Contained breathing apparatus (2

Nos.)

� Chemical Suits (2 Nos.)

� Air line breathing apparatus in RG/HF Plant / CMS/HFC-134a/P2/P6/P10 Control Room is

available. The Air is supplied through a compressor installed near Engineering stores and at

HFC compressor house . The line is kept pressurised. However in case of emergency the

breathing air will only be used after considering & ensuring the wind direction & possible

contamination. Depending on the wind direction utility JE will ensure operation of

compressor for contamination free supply of air.

There is no hot line provided directly with District Magistrate / Police Control room / Fire

brigade / Emergency ward of hospital, etc. However, they can be communicated immediately

through STD lines. Non-stop power supply (UPS) has been provided in all the Control rooms.

Emergency lights are also available in control room and critical plant floors. Meteorological

information is available in Laboratory.

Four nos. Assembly points are located at four different directions.

1. Lawn in front of Management Block

2. Lawn near HFC-134a Plant

3. Lawn in front of R & D

4. Lawn near new empty drum godown ( SCB area)

Boards have been displayed at proper site to indicate the Assembly points.

Roll call/ Head count is done at Assembly point (during emergency).

7.2.5.1.3 Communication System

1. Internal & External Telephones

2. Speakers for announcement

3. Mobile Phones

4. Walkie-Talkie

5. Hot Lines/ Emergency Telephones

Internal & External Telephones

Internal & external phones are available in all plant Control Rooms, offices and department. List of

telephone Nos. is as per Telephone List.

Speakers for Announcement

By dialing "100" from the phone, announcement can be made from phone. This announcement will

be audible through various loudspeakers installed at stretegic locations inside the premises. For

announcement in limited area (Restricted to a particular plant only) Five different Telephone Nos.

are provided i.e. for RG-HF, CMS, HFC-134a, CPP & SCB area.




Mobile phones

Mobile phones are provided to various key employees in the organisation. List of Mobile no. is

available in ECC and Security office. These employees are available 24 hours on Mobile phone & can

be contacted anytime. "

Walkie-Talkie

Walkie Talkie sets are available in all Control Rooms. Person on field duty carries Walkie Talkie. He

can contact Control room immediately for any communication related to incident/ emergency.

"Hot lines/ Emergency phones

Hot lines/ Emergency phones are provided in internal telephones for un-interrupted / direct contact

from one Control Room to another Control Room, Chlorine area, Elect Dept & Security office."

TABLE 7.1

List Internal / External Communication Equipment

ITEM Total Nos.

Location Remarks

Internal Telephones 196 All Departments, offices, Control Room

Complete list is available with Electrical Deptt.

Hot Lines/ Emergency Phone

9 Plant Control Rooms, Cl2, electrical & Security

Complete list is available with Electrical Deptt. & C/R

Speakers for Announcement

70 Control Rooms, offices & Plant Complete list is available with Electrical Deptt.

Mobile Phones >60 Individual Complete list is available with Electrical

Deptt.




SIREN for Emergency

To declare ON-Site Emergency, Siren is provided in different Plant/ departments. Siren can be

blown from the Control Rooms and Security offices. Green Colour switches are provided and shall

be used by pressing according to Siren Codes.

SIREN Code

Declaration of the Emergency: 10 Second On -> 5 Second off -> repeat the same Three times.

Declaration of all Clear: A long Hooter for 60 Seconds

7.2.5.2 ALERTS LEVEL

On the basis of potential consequence and area affected the Three Alerts levels are envisaged

1. Level-1

2. Alert Level-2

3. Alert Level-3

ALERT Level-1

If the emergency is confined to the Same Plant/ Section and it is not affecting the other Plants and

departments in the vicinity the Alert Level would be ALERT level-1

ALERT Level-2

If the Emergency is such that it is going to affect the neighboring Plant in the vicinity the Level of

the emergency would be ALERT Level-2

ALERT Level-3

If the emergency is having potential to affect the periphery and can go beyond the boundaries of

Factory then it is ALERT Level-3 emergency.

7.2.5.2.1 Criteria for Proclaiming Major Emergency/Deciding the ALERT Levels

A major emergency situation can occur in the event of:

a) Fire:

Fire can take place inside the plant/ various departments / Stores/ Paints, solvents and Oil

Storage yards offices and other areas inside the site.

b) Explosion:

Explosion followed by fire or fire followed by explosion. These could take place inside the

plant/ Storage yards & Stores.

c & d) Release of Toxic/ corrosive Gas or Bulk spillage of Chemicals:

The released of toxic/corrosive gas/ chemicals can create a major emergency situation in

view of the quantities stored, the procedure outlined to handle the emergency situation is to

be followed with respect to:

• Evacuation and assembly of personnel to a safe place.

• Taking appropriate steps for bringing the situation under control.




7.2.5.2.2 Alert Level Decision

Table – 7.2

Alert Level

Shifts LEVEl-1 LEVEL-2 LEVEL-3

A-Shift Shift Incharge of the

respective Plant

Plant Manager Technical Coordinator

B & C Shift Shift Incharge of the respective Plant

Shift Incharge of the respective Plant


Sunday & holiday Shift Incharge of the respective Plant



TABLE 7.3

Actions in Alerts Level

ALERT Levels Level-1 Level-2 Level-3

Actions Shift incharge should visit the site & start action to isolate &

mitigate.

Shift incharge should start assessment, isolation & mitigation & then inform Plant

manager.

Plant Manager has to inform Technical coordinator & take advice for declaration of ON-SITE

Emergency.

Communication After controlling the

emergency Shift incharge has to inform Plant

Manager

-Shift Incharge has to inform

Plant Manager. -Plant manager has to inform Technical Coordinator.

-After controlling the emergency Tech. Coordinator

has to inform Chief Coordinator.

Shift incharge has to inform Plant

Manager & Emergency organissation chart has to be followed.

Assistance Required

-Maintenanace -Security for Fire fighting/ Running of

Fire water Pump.

-Maintenance -Security for Fire Fighting/ Running of Fire pump

-ERT members -First Aid (Ambulance).

-EHS Representative

As per Emergency Organisation chart

ALARM/Siren Code

No Siren No Siren Siren Code :

"10 Second ON", "5 Second OFF"

(Three Times)




7.2.5.2.3 Steps to Be Followed in Case of Alert Level-3 Emergency (On-Site Emergency)

� After getting the information of major gas leak / fire, the control room operator will contact

the Plant Manager (Incident Controller) and will inform him about the situation. Incident

Controller then inform the Technical Coordinator (TCO).

� The TCO will quickly assess the situation and immediately inform CCO to declare Emergency.

� In case CCO & TCO both are not available, the next line Manager / Supervisor will decide and

declare the emergency, especially in the night.

� TCO will ask Shift person in Control Room /main Gate to press the Emergency Siren (10

second Press – 5 Second Release – 10 Second Press – 5 Second Release – 10 Second Press-

Release) to declare LEVEL-3 (On Site Emergency).

� After hooter, he would announce on P.A. system about the nature of Emergency and

location of Emergency. If required, he would take steps to shut down the plant.

� TCO will inform the CCO about further developments and act as per CCO’s advice.

� TCO will ask one Process J.E. & one Mech. J.E. to wear cover-all emergency safety suits (if

required) along with SCBA and go to field immediately to control the leakage as well as

rescue the victim (if any) from the place of accident.

� On hearing siren / announcement, the Fire & Rescue team and Ambulance shall reach the

concerned site immediately and contact incident Controller/ TCO for instructions.

� TCO will ask the Fire & Rescue team to send the victim (if any) to Medical Center in

ambulance.

� On hearing siren / announcement, a Security guard shall immediately rush and start the fire

water pump.

� On hearing siren / announcement, the Officers with various responsibilities as per

Organization Chart for Emergency Control, shall reach their designated places and report to

the concerned coordinators for instructions. They shall discharge their duties

� On hearing siren / announcement, all other persons present in the plant ( those who are not

playing any role in mitigation of emergency) would rush either opposite of wind direction or

right angle to the wind direction (whichever is suitable depending upon the emergency

situation i.e. spread of toxic release or fire ) and assemble at the safe “Assembly Point”.

� Further activities would proceed accordingly to the instructions of CCO, in case of

evacuation or otherwise.

� When the Emergency will be over, TCO will inform the same to CCO and after getting

consent from CCO will ask shift person / main gate to press the hooter for all clear signal

(Press the hooter for 1 minute continuous without releasing it).

� After that Incident Controller will arrange to announce on P.A. System that the Emergency is

over now & It is “ALL CLEAR.”

� If any visitor is inside the factory, it will be the responsibility of the concerned officer with

whom he will be attached, to send him at the “Assembly Point” along with a responsible

person.

� Specific emergency action is to be taken as per scenario based action plan.




Note:-

� In absence of Chief Co-ordinator, Mr. Himanshu Shukla will function as CCO.

� In absence of Admn. Co-ordinator, Mr. Lalit Pratap will function as ACO, C & LO as well as

Fire & rescue officer.

� In absence of Tech. Co-ordinator, next lower level (SS Pundir / SC Joshi / S L Bains / Hirdayesh

Kumar / Dinesh Gangawane / Rahul Gupta/ Dharam Pal Bajaj) will function as TCO




� In absence of Safety Co-ordinator, Sanjay Katiyar will function as SCO as well as SO.

� In absence of responsible persons in any shift as earmarked for Emergency Officers, the

next lower level person available/ present in shift will assume the respective functional

duties.

NOTE:

� Plant Shift Manager / Shift Incharge will remain CCO till the arrival of Mr A K Goel. Similarly

the responsibilities on all other officers get transferred as and when the respective

Deptt./Section heads arrive at site.

� In absence of responsible persons in any shift as earmarked for Emergency Officers, the

next lower level person available/ present in shift will assume the respective functional

duties.




7.2.5.2.4 Responsibilities for on Site (Level-3) Emergency Control

Chief Coordinator:-

1. Shall immediately go to Emergency Control Center and contact Technical and Administrative

Coordinators.

2. Will direct the plant from the Emergency Control Center.

3. Assess the situation and decide and initiate actions if not done already.

4. Ensure proper communication to inside & outside emergency services.

5. Take direct operational control of the plant not affected by incident.

6. Determine probable course of action and review the situation to initiate further actions

accordingly.

7. Direct shutting down of the plant & evacuating the people, if required.

8. Shall be the only authority to speak and submit report to the outside media like press,

government officials, etc. on behalf of the company.

9. Shall take assistance from Technical and Administrative Coordinators and shall consult Safety

Coordinator, if required.

10. Control rehabilitations efforts after the emergency are over.

Administrative Co-ordinator :

1. Shall immediately go to Emergency Control Center and report to Chief Coordinator for

instructions.

2. Shall coordinate the smooth functioning of Communication / Liaison Officer, First-Aid

Officer, Fire/ Accident Rescue Officer, Guard Officer and shall guide them in case of any

need.

3. Shall keep chief coordinator fully informed about the progress of activities of the Emergency

Officers under his control. Shall seek further instructions and implement them.

4. Must see that there is "NO PANIC" in and outside the factory, so that Emergency Control

can proceed without any hindrance and all the agencies concerned work in unison.

5. Ask administrative assistant to take Roll Call of all assembled at Assembly Point.

6. In consultation with chief coordinator

� Inform Police

� Inform neighboring factories

7. Communicate the incident to statutory authorities like factory Inspector, district magistrate

etc. and insurance company.

8. Communicate with Local administration to provide assistance in communication and safe

evacuation of nearby villagers.

Technical Co-ordinator:-

1. Shall immediately go to the control room of the concerned plant, take stock of the situation

from Operations Officer and incident controller, contact Chief Co-ordinator at Emergency

Control Center at the earliest and apprise him about the nature and extent of Emergency and

any need for support.




2. To assess the scale and severity of the incident

3. Shall coordinate the smooth functioning of Operations Officer, Mech. Maintenance Officer,

Utility Officer, Electrical Officer, Stores Officer, Inst. Officer. Safety/ Environment Officer and

shall give them guidance.

4. Shall keep Chief Coordinator fully informed about the progress of Emergency Control

activities under his control. Shall seek further instructions and implement them.

5. Must see that the affected plant is shut-down safely, damage is restricted from spreading,

injured persons are safely evacuated and subsequently necessary repairs are carried out at

the earliest, once the situation comes within control.

6. Shall arrange for declaring all clear after getting information from incident controller.

7. To preserve evidence that would facilitate any subsequent inquiry into the cause and

circumstances of the emergency.

Incident Controllers

1. After getting information about any untoward incident, incident controller should

immediately rush to incident site.

2. After assessing the situation contact Technical Coordinator & decide to declare On Site

(Level-3) Emergency.

3. Shall go to incident site with required PPE's and direct the mitigation team for isolation.

4. Shall provide guidance to fire fighting crew & rescue crew for effective mitigation.

5. Arrange for the search of causalities.

6. Ascertain the source, amount and extent of leakage; Assess possible hazards to human

health and the environment, both inside and outside the factory, and inform Technical

Coordinator.

7. Shall keep updating the Technical coordinator about situation at Incident site. Seek further

help required from technical coordinator.

8. After controlling the emergency he should inform Technical coordinator about all clear.

9. Arrange for decontamination of the site.

Safety Co-ordinator:

1. Shall immediately report to Chief Co-ordinator at Emergency Control Center for assistance.

2. Shall assist Chief Co-ordinator for systematic implementation of "Emergency Plan", both

strategic and logistics.

3. Shall provide safety related information to Chief Co-ordinator.

4. Shall advise Chief Coordinator as to change in location of ECC or Assembly point depending

on wind direction and extent of emergency.

5. Shall advise Chief Coordinator as an independent observer, where are the shortfalls, or

the activities which need immediate attention and support.

6. Take note of the sequence of events/ reporting/ action taken against time.

7. Assess the initiative taken by different persons, their understanding of the situation/ actions

and find out shortfalls / deviations.




Operations Officer (Shift Incharge-Process):

1. After getting information regarding any untoward incident, wear appropriate PPE's & visit

the site to assess the scale of emergency

2. Contact Incident Controller to brief about incident & take instruction/ decision for declaring

On-Site Emergency

3. Ask Panel JE/ Main Gate Security In charge to press the button for Emergency Siren (10

second Press – 5 Second Release – 10 Second Press – 5 Second Release – 10 Second Press and

then Release ) to declare Emergency. Announce Emergency (Exact location & type ) through

PA system. Also announce the wind direction & safe assembly point to be used.

4. On hearing siren all process person should leave the affected plant field area and

assemble at Control Room.

5. Ask one J.E. to wear all cover suit with SCBA.

6. Switch off A.C. of Control Room.

7. Be in touch with the Incident controller & send the J.E. ( wearing all cover suit & SCBA set) to

find out causalities ( if any) in location of accident and evacuate them immediately. Also

send one JE for isolation/ mitigation of the emergecy with all PPE's.

8. Ensure all operating personnel have come to Control room from the affected plant (through

Roll Call).

9. Take safe shut down of the plant with the help of J.E.s, and Engg. People (if required). Note

in log book the timing and sequence of events.

10. Arrange to call ERT members by announcing on PA system.

11. Ask Environment. Officer about wind direction and toxicity level in the atmosphere.

12. Ask safety officer for additional requirement of PPE, if any.

13. When the Emergency is over take clearance from Technical Coordinator to sound the hooter

"All Clear" (Press the hooter for 1 minute then release). Also announce on P.A. system that

Emergency is over now & “ALL Clear”.

Communication/Liaison Officer:

1. Rush to ECC and contact Admn. Coordinator for instructions.

2. Establish contact with all Emergency Officers on Phone for Chief Coordinator.

3. Telephone to external agencies like, Police, District Magistrate, etc. depending on nature of

Emergency and as instructed by Chief Co-ordinator.

4. Call Doctor to come to factory immediately by his own vehicle.

5. Receive reports on movement of transport and situation at Gate and inform Admn.Co-

ord./Chief Co-ordinator.

6. Arrange emergency vehicle as required by Dispensary and instruct the driver for sending the

causalities to outside Hospital.

7. Inform Chief Coord./Admn. Coord. on progress of activities being supervised by you

frequently.

8. Direct the Guard Officer on controlling traffic flow at Gate as instructed by Admn. Coord.




Fire/Accident Rescue Officer:

1. Send a Security Guard to ensure that Main Fire Water Pump is running.

2. Send a Security Guard to bring all security personnel from barrack to report at Main Gate.

Take a Roll Call.

3. Form a fire-fighting/accident rescue team.

4. Send Ambulance at incident site, if required.

5. Take additional stretcher from First-Aid Center to evacuate the affected persons.

6. Rush to the concerned Incident site along with fire and rescue team with required Safety

appliances and report to Incident controller for further instructions.

7. In case of fire involving Methanol / HSD storage tank, operate foam flooding / pouring

system.

8. Contact Admin. Coordinator, inform the status. Ask for further Instructions.

9. If situation is normal, withdraw the team.

First-Aid Officer:

1. Shall immediately contact ECC/ Admn. Coordinator for instructions. Know the nature of

accident.

2. Be available at First-Aid Center. Keep mediacl appliances/ medicines ready.

3. Give First-Aid to Casualties brought. Take help from avaialble first-aiders at site.

4. Shall take instruction from medical officer on phone till arriving factory.

5. Inform communication officer about requirement of vehicle to send the casualties to

outside hospitals for further treatment, if required.

6. Maintain record - Names of persons injured, nature and location of injury, nature of first-aid

given, etc.

7. Help Communication officer in transportation of casualties. Send casualties with an

information slip having informing regarding nature of accident special antidotes (if any)/

already given/ to be used, any other precautions to be taken to treat the persons in hospital.

Guard Officer/ Main gate management:

1. Rush to ECC and report to Admn. Co-ordinator for instructions.

2. Be available at Main Gate and take the control of all vehicles available at Gate in your hand.

Instruct the drivers to :

a) Remain at the vehicle,

b) Carry out instruction given by respective guard officer.

3. Stop entry of vehicle inside factory.

4. Direct flow of traffic from inside the plant to outside the Gate, as per instructions from

Communication Officer.

5. Restrict unauthorized persons so that they should not go near the emergency area with the

help of additional Security Guards who have arrived at Main Gate from barracks.

6. Ensure all contractors’ labors and casual labors, visitors are out of the plant and gone to safe

Assembly point.




Mech. Maint., Utility & Inst. JE/Officers:

1. Send one Utility Technician to Fire Water pump house to start and maintain main Fire

Hydrant Pump in running condition. He will also be monitored level of the fire hydrant

reservoir tank.

2. Rush to control room and report to Tech. Co-ordinator for instructions.

3. Ascertain that all Maintenance personnel have evacuated the affected site. Take a Roll Call.

4. Help Tech. Co-ordinator to perform emergency maintenance. if any, in co-ordination with

Operations Officer.

5. Arrange for auxiliary equipment, if required.

6. Assist Fire-Rescue Crew, along with technicians, as directed by TCO, if required.

7. Shift J.E. will decide the person who will stay at Control room and others to assemble at

Assembly Point.

Stores Officer/PPE management

1. On hearing Siren, report to Administration Coordinator for instructions.

2. Be ready to supply any additional requirement of PPE / Safety gears, as informed by

Communication Officer, from stores.

Electrical Officers:

1. Shall rush to control room and report to Technical Co-ordinator for instructions.

2. Take instruction from Technical coordinator for isolation of Electrical supply for certain area

if required.

3. Ascertain that all Elec. personnel of the affected plant have evacuated from the accident site.

4. Assist Fire & Rescue Crew, along with technicians, as directed by TCO, if required.

5. Ask one JE to ensure uninterrupted electrical supply to Fire fighting pumps.

6. Shift J.E. will decide the person who will stay at Control room and others to assemble at

Assembly Point.

Environment Officer:

1. Rush to Control Room and report to Tech. Co-ordinator for instructions.

2. Instruct one chemist to monitor wind direction and speed. Report same to technical co-

ordinator & safety co-ordinator as well.

3. Instruct one chemist to monitor gas concentration in atmosphere (preferably at assembly

points) and other places as suggested by Tech. co-ordinator / Safety Co-ordinator and report

the same to Safety as well as Tech. Coordinator.

4. On hearing Siren, all other chemists should assemble at Assembly point.

5. Shall arrange to take a Roll Call of the QA people.

CPP Officer

1. Remain at Control Room

2. See the wind direction

3. Coordinate with Chief coordinator




4. If wind direction is towards CPP, ask only essential person to stay at control Room & rest to

go to suitable assembly point.

5. Get ready for Emergency Shut Down

6. If chances of toxic gas coming towards Control Room Ask operating person to wear SCBA

7. Wait for instruction from CCO & brief him about the situation

8. After All clear, restore the plant

Safety Officer

1. Rush immediately to Control Room and report to Technical Co-ordinator.

2. Help Operation J.E. to wear Safety suit with SCBA.

3. Keep open all safety cup boards.

4. One Safety Officer should go to incident site with required PPE's & assist incident controller.

5. Help the staff in replacement of safety equipment, if required, or get more PPE from Stores

Officer.

6. Watch wind / gas leak profile and advice Tech. Co-ordinator accordingly.

7. Shall note the sequence of events and time in a pad for analysis.

8. Assist TCO in safety related matters.

Contractor/Casual Laborers:

1. Contractor of the affected plant would immediately ask all his laborers to leave the plant

and go to the Assembly Point. Similarly, Guard Officer would ensure all casual workers

are out of the affected plant and have gone to Assembly Point.

2. Take a Roll Call and ensure all contract worker have come out of the plant.

3. Act as per instructions from Admin Co-ordinator.

Visitors

1. All related officers are required to direct/ help concerned visitor to reach safe assembly

point.

2. Visitors are required to remain at Assembly point till further instruction/ all clear Siren.

7.2.5.2.5 Relay Communication for Alert Level-3 (in case of On-Site Emergency)

In case of On Site emergency it is not possible for the incident controller to tackle the emergency &

simultaneously communicate the emergency to higher-ups. To facilitate Incident Controller

following relay communication shall be followed.

Proposed expansion of Multi-Purpose Plant/Fluorospeciality Plant (3000 TPA to 6000 TPA); Installation of new generation Refrigerants & Refrigerant Blends Plant (90,000 TPA) and Change in Product Mix of Chloromethanes and

HFC134a At Village & P.O.-Jhiwana, Tehsil-Tijara, District-Alwar (Rajasthan)


TABLE 7.4

List of Communication Numbers Bhiwadi Site

NAME TEL

NO.

MOBILE NAME TEL

NO.

MOBILE NAME TEL

NO.

MOBILE NAME TEL

NO.

MOBILE

EMERGENCY HOT LINE AND PA NOS R22/HF INSTRUMENTATION R&D

PA-Common 100/4

00

Spare 190 Mr.S.S.Sharma 260 9910043656 Spare 340

PA-R22/HF 101 Mr.S.S.Pundir 191 8003290532 Mr.Asai Thambi 261 9799492498 Mr. Bhupinder

Singh Rana

341

PA-CMS 102 Spare 192 Mr.Bacchu Singh 262 9799492698 Spare 342

PA-CPP 700 Spare 193 JE- Instrument-

R134a

263 Mr.Rajsekaran 343 981820091

1

PA-R134a 600 Mr.A.K.Singh 194 9929712328 JE- Instrument-

SCB

264 8003090265 Mr.Kapil Kumar 344 981012790

8

PA-SCB 105 Mr.K.Singhal 195 9929712318 Instrumentation

Lab

265 8003090261 Synthetic Lab-3 345

HOT LINE-M.Gate

112 R22 Control Room

196 512552 8003090419/20/80

03593830

Instrument Lab- SCB

266 Mr.RP Balaji 346 8003090856

HOT LINE-R22/HF

113 HF Control Room

197 Walki talki 267 Mr.Surender Dhingra

347 9810662293

HOT LINE-CMS 114 Spar Control Room

198 Instrument W/S 268 Dr.Niharika Singh

348 9928497138

HOT LINE-R134a 115 ATF Control

Room

199 SALES & FILLING Synthetic Lab-2 349

HOT LINE-CPP 116 DHF Control

Room

200 Mr.Pratap Singh 270 9818006663 Mr.Jose George 350 99100746

64

HOT LINE-SCB 117 ETP Plant 202 Mr.R.K.Thapliyal 271 9680302277 Mr.H.P Gupta 351 80030908

57

HOT LINE-ELECT-FCB

118 Old MTF 203 Mr.K. Srivastava 272 R&D Plant 352

HOT LINE-P-6 119 R22 Filling 204 8003394711 Filling Station

Mr.S.K.Dixit 273 R&D Center (Pantry)

353

HOT LINE- CL2 120 Jug Filling 205 Mr.Bhagwan Das 274 Synthetic Lab-1 354




NAME TEL NO.

MOBILE NAME TEL NO.

MOBILE NAME TEL NO.

MOBILE NAME TEL NO.

MOBILE

EPBAX-OPERATOR

9 Drum Filling 206 Spare 275 Conference Room

355

ADM BLOCK Tonner Filling 207 Mr.S.K.Gupta 276 9829669894 Mr.Manoj Kumar

356

Mr.Prashant

Yadav

130 T.O.Plant 208 Mr.Suresh

Kumar

277 9929597584 High-pressure

Lab

357

Mr.Rajeev

Marwah

131 9810747

954

CMS TECHNICAL SERVICES Mr.Man Singh 358 992925557

7

Mr.Neeraj Chandna

132 9818200914

Mr.S.C.Joshi 210 9958080275 Mr.Himanshu Shukla

280 9829349994 Mr.Kapil Sharma

359 9910027793

Mr.Manoj Mishra

133 9810742832

Mr.R.Bhatnagar 211 Mr.Anil Ojha 281 Analytical Lab 360

Mr.Rajesh Trpathi

134 9818200917

CMS Control Room

212/213

519108 8003090417/18

Mr.M.Gundal 282 Spare 361

HOW Conf. Room

136 CMS Pantry 214 Mr.Siddharth Bhawal

283 8003092132 R134a R&D Maint.

362 9829629910

Pantry 138 CL2 Unloding 215 Mr. Mukesh Dixit 284 9680495222 R134a R&D LAB 363

CEO Conf. Room

139 CL2 C. ROOM 216 IT System 285 9928073912 Dr.Chandresh Soni

364 8003090858

Mr.Rohit Srivastava

141 9950206502

MTF 217 P.Conf. Room 286 R134a

PERSONAL& HR MECHANICAL & UTILITY Mr.Krishan

Bahadur

288 Mr. L S Bains 480

Mr.Rajbir Singh 150 8826288

933

Mr.Amit Pandey 220 9971091404 Pantry 289 Mr.T.K.Barik 481 88900905

22

Mr.S.Khandelwa

l

151 9829349

993

Mr.Hari Om

Singh

221 8003091650 QA LAB Mr.Abhishek/Mr

. SKManna

482

Mr.Rahul Parasar

152 8003090195

Mr.Pankaj Garg 222 8003093945 Mr.P.Varshney 300 9950259643 Mr.Susheel 483

Mr.A.K.Gomes 153 Mr.S.Karmakar 223 8003093028 Mr.S.C.Tomer 301 9799396150 Sub-Station 484

Mr.S.K.Singh 154 9799296 Mr.Sandeep 224 8003091649 Spare 302 Control Room 485/4 512145




NAME TEL NO.

MOBILE NAME TEL NO.

MOBILE NAME TEL NO.

MOBILE NAME TEL NO.

MOBILE

530 Dalal 86 8003390136/37

Mr. Mumtaz Masood

155 8003094036

Mr.Gaurav Jaiswal

225 8003593670 Wet Lab 303 UTILITY 487 8003090365

Ms.Shipra

Rathore

156 8003094

483

Mr. Ravindra

Yadav

226 Chemical Lab 304 Mr.M.K.Sharma 488

Canteen 158 JE- Mech R22/HF 227 9799879729 QA Lab 305 QA Lab Cabin 489

ADMINISTRATION JE- Mech R134a 228 8003090867 Mr. Amitosh Singh

306 8890090526 HOG 490

Mr.Lalit Pratap 160 8003091

667

JE- Mech SCB 229 9829849910 SCB Conference

Room

491

Mr.Sanjay Sain 161 8003090

634

Mech W/S

R22/HF

230 Mr.A.K.Goyal 310 9829409576 Mr. Ratnesh

Kesari

492 957191299

9

Mr.Joy Thomas 162 Mech W/S CMS 231 Mr.S.S.Sharma 311 9928345082

Main gate 163 Tool Room 232 Mr.Rai singh 312 9001098645 CPP

Main gate 164 8003090635

Mr.D.N.Gupta 233 9001792691 Mr.P.N.Goyal 313 8003092133 Spare 401

Material Gate 165 9829349990

Utility R22/HF 235 9799879731 Control Room 314/315

519166 8003390135

Mr.Rahul Gupta 402 8003090356

Casual Gate 166 Utility R22/HF 235 9799879731 JE-Process 316 Mr.Ganesh Padole

403 8003091248

Weigh Bridge 168 Utility CMS 236 Dinesh

Gangawane

328 8003951118 Spare 404

SARD 169 Boiler House 237 Utility-HOG 318 8003390131 CPP Mech

W/Shop

405

Dr.Anil Agarwal 170 9414366

495

Mr. R.C.Sharma 238 RM Store 319 Control Room 406/4

07

98293384

85

Time Office 171 Mr.Sudhir Baranwal

239 9001297163 ETP 320 Boiler Fire 408

Medical Center-OPD

172 Mr.Ayush Bhardwaj

326 8003090233 Conference Room

321 Boiler House 409




NAME TEL NO.

MOBILE NAME TEL NO.

MOBILE NAME TEL NO.

MOBILE NAME TEL NO.

MOBILE

STORE ELECTRICAL Pantry 322 D.M.W House 410 8003094035

Mr.J.K.Biswas 180 9818007044

Mr.A.Nagori 240 9829223494 Filling station 323 Sub-Station 411

Mr.Satish Arora 181 97840115

71

Mr.Saurabh

Chauhan

241 8003593669 FG Godown 324 Shift Incharge 412 80030940

31

Mr.Rajesh Singh 182 97840115

79

Mr.A.K.Singh 242 8003390133 Mech.W/S 325 CPP Mech 413 80030940

34

Mr.N.K.Mathur 183 Mr.Rajesh Yadav

243 9799879727 P5 Plant JE 8003993336 Conference Room

414

Mr.C.P.Adlakha 184 9818200912

JE-Electrical -FCB

244 9799879734 Mr .Hirdesh Kumar

370 9784003630 C.H.P.Operator 416

Mr.C.Nair/Mr.Dinesh

185 8003494699

SCB DG House 430 P6 & P9 Pilot Plant

Mr.Tushar 186 SCB MCC ROOM 245 Mr.Satrughan Gupta

421 8003092336 Mr.Nilesh Shah 330 8003090629

Mr.A.Sharma 187 8003494

688

JE-Electrical -

SCB

246 9829829910 P6-JE

Mechanical

422 8003092134 Mr.Ajay

Bhardwaj

331 97993967

99

CIVIL JE-Electrical -

CPP

247 8003094033 Control room 423 9001298949 Spare 331

Mr.Pankaj Sharma

252 9784596384

Mr.R.K.Bisaria 248 9812183826 Control room 424 Spare 332

ACCOUNT Motor Room 249 Spare 425 Sub-Station/Mech

333

Mr.Chander Sain 255 800309095

DG House-FCB 250 9829534466 Spare 426 Spare 334

Mr.Tarun Kumar 256 DG UPS House (R134a)

251 Spare 427 Mr. Dharam Pal Bajaj

335 9001895891

Motor Room (

SCB)

253 P6-JE

Mechanical

428 8003092134 Control Room 336 800309141

7

Mr.Subham-P2 8003092337




NAME TEL NO.

MOBILE NAME TEL NO.

MOBILE NAME TEL NO.

MOBILE NAME TEL NO.

MOBILE

SAFETY Mr.sarad -P3 8003294468

Spare 290 Mr. Jitendra

Silawat

429 9829145588 Mr.Pankaj

Jangra

337 99502073

57

Mr.S.Katiyar 291 9829893935

P-10 0.0Mtr/3Mtr Floor

431 Mr.Shailendra Namdeo

338 9799297056

Mr.Kunwar Pal 292 8003095828

Spare 440 8003092336 6.0Mtr/10.9Mtr Floor

432 Instrument lab 339 8003091416

Spare 293 P-10 Process 441 8003090632 12/15/18Mtr Floor 433

Mr.Neeraj Bhatnagar

294 9799497760

1st floor 442 Mech.W/S 434

QA Lab 443 Emergency Numbers

Ground Floor 444 R134a Control

Room

01493-517145 Facilities Available with

Intercom

Head Office

(Gurgoan)

0124-4354400 P10 Control

Room

445 8003090632 R22 Control

Room

01493-512552 To Lock Phone : Dial *66 PASSWORD

Factory LandLine

01493-517838,517839

2nd floor 446 CMS Control Room

01493-519108 To Un Lock Phone : Dial #66 PASSWORD

01493-512714,512715

Conference Room

447 CPP Control Room

09829338485 Auto Call Back: Flash + star(*)58

Store Fax 01493-511707 Change Room 448 SCB Control Room

01493-519166 Call Transfer: Flash + Extension No.

SCB Fax 01493-511837 MCC Room P10 449

Sales

Coordination

01493-512717 Call Pick UP:Star(*) 59 + Extension

No.




M/s. SRF Limited 29 J. M. EnviroNet Pvt. Ltd.

1 LIST OF OUTSIDE EMERGENCY SERVICES PHONE NO. :

A. FIRE STATION 01493-222700 /512101

B. POLICE STATION Bhiwadi/Tapukara) 01493-220600 /243015

C. HOSPITALS AND AMBULANCE SERVICES

C1 Rahat Hospital 01493-222242, 220395

C2 Civil Hospital 01493-221700

C3 ESIC Hospital 01493-221209

D. ELECTRICITY BOARD 01493-220806

E. RAJASTHAN POLLUTION CONTROL BOARD 01493-221435 /230437

F. FACTORY INSPECTORATE 01493-220782

G. FIRE STATION- Khushkhera 01493-298122

Mobile: 9929141136

2 LIST OF NEIGHBOURING INDUSTRIES :

ARAHAM SPINNING MILL 01493-220485, 220586

HONDA SIEL 01493- 511227

SIEGWERK 01493-243081, 84

3 RESIDENTIAL PNONE NO. OF EMERGENCY OFFICERS :

Location Name Phone/Mobile Nos. To be informed in

case of

Bhiwadi Dr. A.Aggarwal 01493 - 220395, 09829951595 Injury & / or L3

Mr.Sanjay Katiyar 09829893935 L1/L2/L3

Mr. Lalit Pratap 08003091667 L1/L2/L3

Mr. Neeraj Bhatnagar 09799497760 L1/L2/L3

Mr. Kunwar Pal 08003095828 L1/L2/L3

Mr. Anil Goyal 09829409576 L1/L2/L3 in SCB area.

Mr. S L Bains 09001598666 L1/L2/L3 in HFC area.

Mr. Sandeep Dalal 08003091649 L1/L2/L3 in SCB area.

Mr. Hari Om Singh 08003091650 L1/L2/L3 in FC area.

Mr. Rahul Gupta 8003090356 L1/L2/L3 in CPP.

Mr. DN Gupta 09001792691 L1/L2/L3 in FC area.

Mr. S S Pundir 08003290532 L1/L2/L3 in RG/HF/TO

Mr. Rajesh Bhatnagar 09829548256 L1/L2/L3 in CMS

Mr. Ankush Nagori 09829223494 L1/L2/L3

Mr. Pankaj Varshney 09950259643 L1/L2/L3

Mr. Asai Thambi 09799492498 L1/L2/L3

Mr. Hirdayesh Kumar 08003090629 L1/L2/L3 in SCB area

Mr. Dinesh Gangawane 8003951118 L1/L2/L3 in SCB area

Mr. Dharam Pal Bajaj 09001895891 L1/L2/L3 in Pilot Plant

Mr. Ajay Sharma (Store) 08003494688 L3

Mr. Prashant Yadav 09810108669 L3 ( FCB)

Mr. Anurag Jain 09818200920 L3 ( SCB)

Gurgaon Mr. Himanshu Shukla 09829349994 L1/L2/L3





Mr. Rajesh Tripathi 09818200917 L1/L2/L3

Mr. Manoj Mishra 09810742832 L1/L2/L3 in FC area.

Mr. Kapil Kumar 9810127908 L1/L2/L3 in R&D

Mr. Amit Pandey 9971091404 L1/L2/L3

Mr. S.S.Sharma ( Instt) 09910043656 L1/L2/L3

Mr. S.C Joshi 09958080275 L1/L2/L4 ( CMS area)

Mr. Neeraj Chandna 09818200914 L3

Mr. J.K.Biswas 09818007044 L3 & / or Stores

Mr. Rajbir Singh 08826288933 L3

Delhi Mr. Rajdeep Anand 011 - 25740564, 09810096665

L3 ( CTG)

Mr. Rajeev Marwah 09810747954 L2/L3

Other Mr. S Khandelwal 09829349993 L2/L3

Mr. Tapan Barik 08890090522 L2/L3

Head Office 0124-4354400 To inform Emerg. officers

7.2.5.2.6 Equipment having Potential for On-site Emergency

Following aspect could be the criteria for declaring emergency:

� Size of the leak/fire

� Spread of the leak ( Pr./Size/Temp./Nature)

� Man power in the plant

� Duration of the leak

� Support available in the plant

Following vessels could be considered as potential source for emergency:

RG Plant

S.

No.

Tag No. MOC Capacity (MT) Temp. (OC) Pressure

(Kg/Cm2)

1 R-22 Reactor Inconnel 3.6 62 10.5

2 Catalyst hold tank CS 6.9 60-80 5.0 - 7.0

3 Catalyst stripper reboiler CS 1 82 5

4 HF Vaporizer Inconel 0.5 110 13

5 Catalyst stripper Inconel 0.5 65 10.5

6 HF feed tank CS 8 Ambient 2

HF Plant

S. No

Tag No. MOC Capacity (MT) Temp. (OC) Pressure (Kg/Cm2)

1 Crude HF tanks CS 3.5 0-10 -100 to -150 mm WC

2 Reboiler of Ist dist. Column CS 1 70 3.0

3 Reboiler of IInd dist. Column CS 1 65 2.0

4 PSA tank A-20 3 95 -15 to -20 mm WC





5 HF day tanks CS 8+8+8 Ambient 2.0

6 HF main storage tanks CS 60+60+40+60 Ambient 2.0

CMS Plant

S.

No.

Tag No. MOC Capacity (MT) Temp. (OC) Pressure

(Kg/Cm2)

1 RQ 500 Monnel 15 55 14.5

2 C1 day tanks CS 9+9 Ambient 9.0

3 Chlorine bullets CS 70+70+70 15 to 20 9.0

4 RQ-603 CS(Glass

lined)

10 160 3.2

5 Chlorine tonner CS 0.9*190 Ambient 9.0

6 Methanol tank CS 170+170 Ambient +500 mm

WC

HFC_134a Plant

S. No.

Tag No. MOC Capacity (M3) Temp. (OC) Pressure (Kg/Cm2)

1 T-241 column reflux drum(V-242) CS 1.17 50 2.5

2 HF Distillation column (T-241) CS 1.0 60 2.5

3 Moisture removal column(HF)(T-

251)

PTFE lined 0.1 55 2.0

4 Reactor R101 Inconnel/ CS 18.91 275 5.0



7 Reactor R104 SS316L 2.8 200 1.0

8 Therminol Expansion tanks(V101) CS 4.0 275 10.0



Thermal Oxidation Plant

S. No.

Tag No. MOC Capacity (Cu Meter)

Temp. (OC) Pressure (Kg/Cm2)

1 Hydrogen Trolla MS 1700 Ambient 150 Kg/Cm2

Specialty Chemical Business

P2 to P4 Plants

1 Chlorine Tonner CS 900 Kg Amb 9.0 Kg/Cm2

2 HF tank- V2131/ V2136 SS 2.1 MT Amb 1.0 Kg/Cm2

3 Fluorination Reactor V-3132-A/B SS 2.5 M3 350 0C 17.0 Kg/Cm2

4 Flammable tanks on G. floor SS 1-2 MT Amb Atm.

5 Flammable Storage shed (Barrels) HDPE/SS/GI 200 Kg Amb Atm.

6 Br2 Vessel Glass 100 Ltrs. Amb Atm.

7 Spent H2SO4 Storage Tank V9006, V9007

MS 16 MT, 14 MT Amb Atm.

8 Crude TFA tank ( V-2151) A/B PP/FRP 2M3, 1.4 M3 Amb Atm.

P6 to P9 Plant

S. Tag No. MOC Capacity (Cu Temp. (OC) Pressure





No. Meter) (Kg/Cm2)

1 R-9021A ( P8 reactor) SS316L /

SS304

3.2 Max 61°C Max 0.1

2 R-9021B ( P8 reactor) SS316L /

SS304

3.2 Max 61°C Max 0.1

3 Ethanol storage Tank ( V-6096) CS 20 Ambient Max 0.1

4 ETFA storage tank (V-9112) SS316L 20 Ambient Max 0.2

5 TFEMe storage tank (V-6051) SS316L 22 Ambient Max 0.8

CREDIBLE SCENARIO FOR EMERGENCY:

PLANT : RG/HF/TO

S.N. Chemical Scenario Alert Level

1 HF Storage Tank failure 3

2 HF Pipeline Failure 2 or 3

3 HCl Storage Tank failure 3

4 HCl Pipeline Failure 2 or 3

5 H2SO4 Storage Tank failure 3

6 H2SO4 Pipeline Failure 1 or 2

7 Hydrogen Fire in Hydrogen 2 or 3

8 DHF Spillage of DHF 1

PLANT : CMS

1 Chlorine Tonner valve/ body leak 2 or 3

2 Chlorine Tonner unloading tube leak 1 or 2

3 Chlorine Bullet leak/ Failure 3

4 HCl Gas & C1 Leakage / failure of Photochlorination Reactor

2 or 3

5 HCl Gas & C1 Leakage/ failure of Hydrochlorination

Reactor

2 or 3

6 Methyl Chloride (C1) Fire in C1 storage Tank 3

7 Methanol Fire in Methanol tank 3

8 Methanol Fire in tanker during unloading 2 or 3

9 LSHS/HSD Fire in LSHS/HSD Tank 3

10 Chloromethanes Leakage/ failure of storage tanks 2 or 3

PLANT: Captive Power Plant

1 Coal /Husk File in Coal / Husk Storage 1 or 2

PLANT: SCB

1 Methanol, Fluorobenzene, Toluene Fire in Methanol, Toluene or Fluorobenzene storage tank

2 or 3

2 Bromine Br2 vessel failure 2 or 3

3 Bromine Br2 Bottle 1 or 2

4 TFA TFA storage tank failure 2 or 3

5 BN, PFBN BN/PFBN leakage from fluorination reactor

2 or 3

6 TCAC Leak in TCAC tank from pipeline 1 or 2





7 Toluene Fire in Toluene storage shed 1 or 2

8 Hot Oil Fire in Hot Oil 1 or 2 or 3

9 Ethyl Acetate, Fluorobenzene, Benzonitrile, Monoglyme

Fire in EA, BN, Fluorobenzene & Monoglyme storage shed

1 or 2

10 FS Product -Flammable Fire in Product storage shed 1 or 2

11 Chemical Storage Fire in Chemical storage yard 1 or 2

12 Ammonia Ammonia cylinder leakage 1 or 2

13 Ethyl Alcohal Fire in Ethyl alcohal Tank in MTF 1 or 2 or 3

14 P-61, Ethanol Fire in Tanker of Ethanol / P-61 1 or 2

PLANT: HFC -134a Plant

1 HOG tank Fire in HOG drain tanks 2 or 3

2 Ammonia Ammonia leak in compressor area 2 or 3

PLANT: R &D

1 R & D Chemicals Fire in R & D Chemicals 1 or 2

Nucleonic Sources

1 Nucleonic Gauges at CMS & RG

Plant

Radiation from the Nucleonic gauges 1

Plant : Pilot

1 Fluorine Cylinder Valve Leak 1 or 2

2 Fluorine process pipe lines leak 1 or 2

3 Fluorine system Fire 1 or 2

4 SF4 Cylinder Valve Leak 1 or 2

5 SF4 process pipe lines leak 1 or 2

7.2.5.2.7 Maximum Inventory of Substances

Plant: RG/HF/TO

Name of Chemical Scenario

HF Storage Tank Failure

HF Pipeline Failure

HCl Storage Tank Failure

HCl Pipeline Failure

H2SO4 Storage Tank Failure

H2SO4 Pipeline Failure

Hydrogen Fire in Hydrogen

Plant : CMS

Chlorine Tonner value/ body leak

Chlorine Tonner value/ body leak

Chlorine Bullet leak/ Failure

HCL Gas & C1 Leakage/Failure of photo chlorination Reactor

Methyl Chloride (C1) Fire in C1 Storage Tank

Methanol Fire in Methanol Tank

Methanol Fire in tanker during unloading





LSHS/HSD Fire in LSHS/HSD Tank

Chloromethanes Leakage/failure of storage tanks

Captive Power Plant

Coal File in coal storage

Fluoro Specialty Plant

Methanol, Fluorobenzene, Toluene

Fire in methanol, Toluene of Fluorobenzene Storage Tank

Bromine Br2 vessel Failure

TFA TFA Storage Tank Failure

BN, PFBN BN/PFBN leakage from fluorination reactor

HFC-134a Plant

HOG Tank Fire in HOG drain Tanks

Ammonia Ammonia leak in compressor area

7.2.5.3 Toxic Release / Spillage of Chemicals

Control Measures inside factory premises:

� All Plants are open and well ventilated.

� Personnel Protective equipment such as SCBA, Air line, Safety goggles, Full suit, Gum boot,

gloves are provided & available in each plant/ section.

� Safety Showers and eye wash fountains are provided at strategic locations.

� Four assembly points are provided where person can be assembled & evacuated if required.

� Red cordoning strips are available for isolating the affected area.

� Remove all non-required persons from the area.

� PA system is available to communicate the emergency.

� Windsocks to assess the air direction have been provided at strategic locations

� Air monitoring to measure the concentration of toxic chemical.

� MSDS of all chemical available in each Plant/ Deptt.

� Leak detectors in place.

� Level & weight monitoring in control room through DCS system.

� Header for CAS system to suck any accidental release.

� Containment dykes

� Emergency trick & transfer pump.

� Empty stand by storage tank available.

� CCTV in critical areas.





7.2.5.4 Fire Hazard

Control Measures inside factory premises:-

� To prevent Fire, the entire factory premises have been declared as "NO SMOKING" zone.

� No spark-producing job is being allowed inside the plant, Tank Farm area & other areas

without Hot Work Permit.

� Emergency Siren is available to warn about Fire emergency. Sound the Siren as soon as

possible after observing the fire. Notify where fire took place. The faster the reaction is, the

easier will be to stop the spread of the fire.

� No vehicle is allowed to move in front of Methanol Tank farm area without having spark

arrestor.

� All plants are covered & protected with 7-kg/ cm2 fire hydrant system.

� Fire-fighting systems installed in the factory are - Portable Fire Extinguishers, Fire hydrant

system and fixed Foam Flooding System to fight Methanol / HSD fire.

� Detailed Layout of the above systems are available in drawings office.

� Detailed Layout of the above systems are available in drawings office.

� Entire fire-fighting system (Extinguishers as well as hydrant system) is inspected/audited in a

phased manner once in a 6 week cycle and record is maintained in 4.4.7_CL-01 (for

extinguishers) and 4.4.7_CL-02 (for hydrant system).

� Once in a year Fire systems Audit is done by External Agency as per 4.4.7_CL-03 and record is

maintained in 4.4.7_F-01.

� The checking of the fixed foam flooding system is done as per 4.4.7_CL-04 under the

supervision of PM MAP (Safety) and PM MWE (Security & Admin.).

� On the Job drill is done once a week and record maintained.

� The Fire sub-process (Security & Admin.) has been given the operational responsibility for

Foam Flooding system, but process person as well as MAP (MP&U) can also operate the

system.

� Any change in the type and/or location of the Fire extinguisher/ Hydrant /Foam system will be

through MAP (Safety) and the change would be sent to drawing office through EWR for

updation.

� Head of P&A carries out monthly review of the Fire Management.

� Trained Fire fighting Security men are available in each shift.

� Four assembly points are provided where person can be assembled & evacuated if required.

� Fire escape staircase is provided in all plants.

� Trained First-Aides & mail nurse are available in each shift.

� Fire proximity suit is available and can be used if valve isolation & other jobs are required in

fire vicinity.

� In case of emergency shift In charge / JE are trained & required to evacuate / shut off the

plants in short notice. They have to follow the responsibility of Technical Coordinator.

� It is in practice to provide earthing before starting loading/ unloading of flammable





chemicals. This is to dissipate static charge.

� Medium velocity water sprinkler system has been provided on Methanol tank.

� After fire fighting operation the water/ foam inside the dyke wall is to be collected in

containers / drum with the help of portable pump & same should be transferred to ETP.

In case of water comes out of dyke wall or if fire takes place in tanker the water used for

firefighting will go to storm water drain. Storm water drain to be isolated and all the water

used in fire fighting shall be collected and transferred to ETP.

7.2.5.5 Safety Appliances

Type of Appliance Nos. available Location

Coverall Emergency Suit 2 RG/ HF Control Room

2 CMS Control Room

1 Cl2 Handling Area

2 FSP

1 HFC-134a

Self Contained Breathing Apparatus 2 RG/ HF Control Room

2 CMS Control Room

2 Cl2 Handling Area

2 FSP

2 HFC-134a

2 CPP

2 Main Gate/ ECC

On Line Breathing Network 4 Chlorine area

1 CMS Control Room

3 CMS Plant

1 RG/HF Control room

5 HF Plant

1 RG Plant

9 SCB Plant area

1 SCB- P2 control Room

1 SCB- P6 control Room

1 HFC Control Room

3 HFC Plant

Compressor for filling the BA Set 1 EHS Department

Chlorine Kit 2 Chlorine area

1 RG Plant

1 FSP

1 Cooling Tower

1 CPP

Safety Showers 98 All plant & floors

Detectors/Sensors





Chlorine 14

Methyl Chloride 12

HF 7

Smoke detectors 75

Manual Call Points 24

CCTV 6 RG-HF Plant

4 CMS

4 FSP

5 HFC-134a

2 Security Gate

2 Marerial Gate

1 Weigh Bridge

1 Casual Entry Gate

7.2.5.6 Fire Fighting & Fire Detection System

There are 60 smoke detectors and 15 manual call points are installed at various locations. These

smoke detectors sense the smoke and give signal to the emitters which are installed in the nearby

location of the sensors. These emitters transmit the signal to the panel installed at ECC-1/ Main Gate

which further gives the location no. of the detector / manual call point with an alarm. The exact

location of the detector or the manual call point from which the alarm was actuated can be

referred from the list depicted near the Main panel of ECC-1/ Main gate.

TABLE 7.5

Smoke Detector Numbers & Location

Smoke Detector No

Location Smoke Detector No

Location

1 HFC CONTROL ROOM 51 HFC ROTRAY UPS PCC

2 HFC CONTROL ROOM 52 P-10 PLANT CONTROL ROOM

3 HFC UPS ROOM 53 P-10 PLANT DCS ROOM

4 HFC BATTERY ROOM 54 P-10 MCC ROOM

5 HFC MCC ROOM 55 P-10 CABLE TRANCH

6 HFC MCC ROOM 56 P-6 PLANT CONTROL ROOM

7 HFC MCC ROOM 57 P-6 PLANT DCS ROOM

8 HFC DCS ROOM 58 P-6 PLANT MCC ROOM

9 HFC CABLE CELLER 59 P-6 PLANT UPS ROOM

10 CMS CONTROL ROOM 60 P-6 PLANT CABLE CELLER

11 CMS MCC ROOM 61 CAN FILLING STATION

12 CMS MCC ROOM 62 CAN FILLING STATION

13 CMS UPS ROOM 63 CAN FILLING STATION

14 CMS DCS ROOM 64 CAN STORAGE BOTTOM

15 CMS HT ROOM 65 CAN STORAGE BOTTOM

16 CPP MCC ROOM 66 CAN STORAGE BOTTOM

17 CPP MCC ROOM 67 CAN BOX STORAGE





18 CPP MCC ROOM 68 CAN BOX STORAGE

19 CPP CONTROL ROOM 69 CAN BOX STORAGE

20 CPP CONTROL ROOM 70 MEZZANINE FLOOR

21 CPP UPS ROOM 71 MEZZANINE FLOOR

22 CPP UPS ROOM 72 MEZZANINE FLOOR

23 CPP BATTERY ROOM 73 FILLING OFFICE

24 CPP CABLE CELLER 74 FILLING OFFICE

25 CPP CABLE CELLER 75 CYLINDER FILLING STATION

26 FSP MCC ROOM 76 CYLINDER FILLING STATION



29 FSP BATTERY ROOM 79 CYLINDER FILLING STATION

30 FSP CONTROL ROOM 80 CYLINDER FILLING STATION

31 FSP DCS ROOM 81 CYLINDER FILLING STATION

32 FSP UPS ROOM 82 CYLINDER FILLING STATION

33 FSP CABLE CELLER 83 CYLINDER FILLING STATION

34 IT ROOM 84 OLD WEIGHING BRIDGE

35 DRAWING ROOM 85 MAIN GATE

36 SUB STATION 76 CYLINDER FILLING STATION

37 SUB STATION 77 CYLINDER FILLING STATION

38 DG PCC ROOM 78 CYLINDER FILLING STATION

39 DG CABLE TRAY 79 CYLINDER FILLING STATION

40 DG CABLE TRANCH 80 CYLINDER FILLING STATION

41 SUB STATION CABLE TRANCH 81 CYLINDER FILLING STATION

42 SUB STATION CABLE TRANCH 82 CYLINDER FILLING STATION

43 RG/HF CONTROL ROOM 83 CYLINDER FILLING STATION

44 RG/HF BATTERY ROOM 84 OLD WEIGHING BRIDGE

45 RG/HF UPS ROOM 85 MAIN GATE

46 RG/HF RC FAN

47 RG/HF CABLE TRANCH

48 HFC ROTRAY DG

49 HFC ROTRAY UPS

50 HFC ROTRAY UPS





Location of Manual Call Points:

TABLE 7.6

Location of Manual Call Points

Zone /element name Location

0010/001 FSP MCC ROOM

0010/002 P-06BLOCK

0010/003 P-10BLOCK

0010/004 RG/HF BLOCK

0010/005 CMS BLOCK

0010/006 HFC BLOCK MCC ROOM

0010/007 HFC ROTARY UPS ROOM

0010/008 SUB STATION MCC ROOM

0010/009 SEQURITY OFFICE

0010/010 CPP MCC -ROOM

MCP-1 CAN FILLING GATE

MCP-2 CAN FILLING DISPATCH GATE

MCP-3 GFS MCC AREA

MCP-4 BACK ENTRY GATE-1

MCP-5 BACK ENTRY GATE-2

7.2.5.6.1 Fire Fighting System (Fire hydrant System)

Fire hydrant system is TAC approved with a working pressure of 7 Kg/Cm2. Jockey Pump maintains

pressure of the fire hydrant network. The fire hydrant is forming main ring in which water is

available from two sides.

7.2.5.6.2 Working of Fire hydrant System

The system operates at 7 Kg/cm2 pressure. In case of pressure drops, first jockey pumps starts at 5

Kg/cm2 pressure and maintains 7 kg/cm2 pressure. In case of any emergency when any fire hydrant

pressure drops below 5 Kg/cm2 and one Jockey pump is not able to maintain pressure, second

jockey starts at 4.5kg/cm2. First main pump starts at 4 kg/ cm2 automatically and it provides

required water for fire fighting. Water reservoir capacity is 1200 m3 which is sufficient for more

than 2 hours fire fighting. Main pump is stopped manually after ensuring the all clear.

Second main pump starts at 3 kg/cm2.

7.2.5.6.3 Power Backup

Three types of Power are available to run the Fire hydrant Pump. Turbine Generator, Diesel

Generator & State Electricity Board. In addition to this a separate Diesel pump is available as

standby & can be operated from the remote operated switch at Security Gate.





TABLE 7.7

Details of Fire Hydrant System

Item Availability

No. of Electrical driven main pumps 2

No. of Diesel driven Main Pumps 1

Capacity of Main Pump 1 273 M3/Hr

Capacity of Main Pump-2 273 M3/Hr

Capacity of Diesel pump 273M3/Hr

Hydrant Pressure 7-8 Kg/Cm2

No. of Jockey Pump 2

Capacity Jockey Pump-1 20 M3/Hr

Capacity Jockey Pump-2 20 M3/Hr

Water reservoir 1200 M3 (two parts, 600 each)

Source of water Ground water

Hydrant Points (Single headed) 193 NOS.

Monitors (Manual) 24 NOS.

Monitor (Remote Control) 08 NOS.

Ozzie Oscillator 1 NO.

Hose Pipe –15 meter length 309

Hose Box 169

Nozzles 85 Nos.

7.2.5.6.4 Foam Flooding System

Foam flooding system has been provided in Methanol Tank & HSD tank. The Foam pourers are

connected with the Fire hydrant system. In case of tank fire individual valve of the foam flooding

system is to be opened manually & thru ventury action foam will be poured in the tanks.

No. of Foam Pourer system: 04 nos. : 2 each in Methanol & HSD tanks.

Details of Water Sprinkler systems : Medium velocity spray systems ( MVSS) have been provided in

following areas:

• Methanol tank Farm ( Both Methanol Tanks)- FCB

• Hydrogen Unloading area- TO Plant- FCB

• Flammable Chemical storage shed - SCB

• HFC main tank farm area- FCB

• P2 Plant Mezzanine Floor- SCB

Water curtain systems have been provided in following areas:

• Chlorine Bullet area- CMS Plant- FCB

• HF Main Storage tanks area- HF Plant- FCB

• NH3 Cylinders storage area- SCB





• P6/P9 MTF area- SCB

• NH3 Cylinders unloading area at P6 Plant- SCB

• Compressors area at HFC Utility- FCB

7.2.5.6.5 First Aid Fire Fighting System

First Aid Fire Extinguishers have been provided all across the Plants & departments. Fire

extinguishers selection has been made according to class of fire in the area. Capacity and Quantity

of Fire extinguishers have been decided according to floor area.

Following is summary of Fire extinguishers available at the site.

TABLE 7.8

Type & Nos of Extinguishers

S. No. Type of Extinguisher Nos. available

1 CO2,4.5 KG 150

2 DCP trolley 25 KG 7

3 DCP,5 KG 290

4 DCP,10 KG 7

5 MECH.FOAM,9 LTRS 21

6 MECH.FOAM,50 LTRS 15

7 ABC,5 KG 130

8 ABC,2 Kg 2

9 CO2,9.0 Kg 11

Total 633

Mobile type Mech. Foam Trolley (200 Lts capacity): 4 Nos. (Two at P6/p9 plant, one each at P3 Plant

and HFC HOG area)

Foam Making Branch: 5 Nos (one each at ECC1, ECC2, Ehs Dept, Pilot Plant & P2 Control Room)

Sand Bucket

Total 104 nos. sand Buckets are available in different plants and storage areas.

7.2.5.7 Control & Mitigation Measures

SCENARIO 1: AHF/ HCl/ H2SO4 Storage Tank failure

Control Measures:-

� Dyke wall provided

� Full Chemicals suit & SCBA provided in the Control Room

� Both RG and HF plants have suction pipe/hose networks connected to CAS to tackle any

eventuality.





Mitigation Measures

S. No. Activity Responsibility

1 Inspect the area, assess the leak & inform to Technical controller & Control room.

JE Operations

2 Technical controller visit the site & assess whether to declare On Site Emergency or not.

Technical Controller/ JE Operations

3 Start Fire pump. Security Utility staff

4 For HF storage tanks start the water sprinkler system JE Operations

5 Ensure that Dyke valve is in close position. JE Operations

6 Wear the Full suit & SCBA. JE Operations

7 Remove all non essential persons. Tech. Coordinator

8 Remove all vehicles in the area. Tech Coord./ JE Operations

9 Instruct emergency combating team to Stay in upwind direction. Tech Coord.

10 Spray firewater from hoses over the fumes to control and contain acid fumes from spreading. Water should not be sprayed directly over liquid

pool.

Security staff/ Operation JE

11 Transfer acid to the stand by empty tank by transfer pumps to the extent

possible. Also, fill acid tankers, if available, by loading pumps.

JE Operations

12 Transfer the spilled acid collected in the dyke pit back to the stand by tank, or to ETP for neutralization.

JE Operations

13 Neutralize the residual acid in dyke, if any, with lime powder. Wash the slurry with water to dyke pit and pump to ETP.

JE Operations

14 For situation beyond control, shut down the plant & evacuate the area. Technical Coordinator

SCENARIO 2: AHF/ HCl/ H2SO4 pipe line failure

Control Measures:-



� Both RG and HF plants have suction pipe/hose networks connected to CAS to tackle any

eventuality.

Mitigation Measures



JE Operations

2 Technical controller visits the site & assesses whether to declare On Site Emergency or not.



4 Isolate the upstream & down stream valves. JE Operations

5 If leak is within the dyke ensure that dyke valve is closed. JE Operations

6 If leak is outside the dyke wall, cordon off the area & make dyke of lime/ sand to stop spreading of the acid.

JE Operations

7 For small and controllable leakages, put suction hose at the point of leakage so as to send acid fumes to Central Absorption System in RG/HF plant.

JE Operations

8 Repair or plug the leakage with wooden/ metallic wedge wearing full chemical JE / Tech. Mechanical





suit with SCBA.

9 Transfer the spilled acid collected in the dyke pit back to the standby tank, or

to ETP for neutralization

JE Operations

10 Neutralize the residual acid in dyke, if any, with lime powder. Wash the slurry

with water to dyke pit and pump to ETP.

JE Operations

SCENARIO 3: Chlorine Tonner valve/ body leak

Control Measures:-

� 12 nos. Chlorine leak detector installed at Tonner unloading, Bullets & CMS plant ISBL area.

� Dyke available in Tonner handling & bullet area

� Chlorine emergency tonner handling kit provided

� Suction cover for Tonner hood provided.

� 2 nos. SCBA set kept at tonner unloading area.

� Suction pipe provided & connected with Hypo system

Mitigation Measures


1. Inspect the area, assess the leak & inform to Technical controller & Control room.

Cl2 area operator

2. Technical controller visit the site & assess whether to declare On Site Emergency or not.


3. Wear SCBA set. Cl2 area operator

4. Identify the leaky tonner. Cl2 area operator

5. Roll the tonner to keep the leaky point at higher position. Cl2 area operator

6. Take the help of other person came from control room. Process JE

7. If leak is minute try to put chlorine kit. JE/ Cl2 area operator

8. Is leak stops after putting the Chlorine kit check the area with ammonia bottle.

Cl2 area operator

9. Evacuate the non essential persons from the area. Technical Coordinator/ Process JE

10. If leak is heavy, put the hood over Tonner. JE/ Cl2 area operator

11. Connect the hood with suction system. JE/ Cl2 area operator

12. Scrub all chlorine venting in hypo system. JE/ Cl2 area operator

13. Check the Chlorine concentration in the surrounding area. JE/Environment officer

14. If liquid Chlorine spilled on the floor, neutralize the same with Caustic solution/ lime.

JE/ Cl2 area operator

SCENARIO 4: Chlorine Tonner unloading tube leak

Control Measures


� Dyke available in Tonner handling & bullet area.

� Chlorine emergency tonner handling kit provided.



� Suction pipe provided & connected with Hypo system.





Mitigation Measures



CL2 area operator

2. Technical controller visits the site & assess whether to declare On Site Emergency or not.


3. Identify the leaky tonner. CL2 area operator

4. Roll the tonner to keep the leaky point at higher position. CL2 area operator


6. Isolate the unloading valve. JE/ CL2 area operator

7. Evacuate the non essential persons from the area. Technical Coordinator/ JE

8. Close the tonner valve. JE/ CL2 area operator

9. Connect the system with hypo system. JE/ CL2 area operator

10. Check the area with ammonia bottle. JE/ CL2 area operator

11. If leak is heavy, put the hood over Tonner. JE/ CL2 area operator

12. Connect the hood with suction system. JE/ CL2 area operator

13. Scrub all chlorine in hypo system. JE/ CL2 area operator

14. Check the Chlorine concentration in the surrounding area JE/ Environment officer

15. If liquid Chlorine spilled on the floor, neutralize the same with Caustic solution/ lime

JE/ CL2 area operator

SCENARIO 5: Chlorine Bullet leak

CONTROL MEASURES:


� Dyke available in Tonner handling & bullet area.



� Suction pipe provided & connected with Hypo system

� Water curtain around Chlorine storage area

� One spare Tank always kept empty for emergency transferring.

� Rupture disc & safety valve

� Temperature indicator & alarm in chlorine unloading line

� Pressure indication & alarm in Tank downstream system

� Air breathing line provided.





Mitigation Measures



Cl2 area operator

2. Technical controller visits the site & assess whether to declare On Site Emergency or not.


3. Start Fire pump. Security staff

4. Wear SCBA set. Cl2 area operator

5. Start water sprinkler system Cl2 area operator

6. Evacuate the area. Technical Coordinator/ JE


8. Put he suction hood & connect the same with hypo system and start transferring the chlorine into empty tank.

Cl2 area operator

9. Restrict the area for non essential persons Tech. Coordinator

10. Use Air line / Trolley mounted breathing system JE Operations

11. Check the Chlorine concentration in the surrounding area JE/ Environment officer

12. Recover chlorine accumulated inside the dyke wall JE Operations/ Cl2 area operator

SCENARIO 6: Photo chlorination Reactor leak

Control Measures

� Methyl chloride & Chlorine leak detector installed all around the reactor to detect ppm of

leak.

� 2 nos. SCBA set kept in CMS control room.

� Reaction stoppage on high pressure of the Reactor.

� Reaction stoppage on high level of the reactor.

� Reaction stoppage on high temperature of the reactor.

� Reaction stoppage on high pressure of the Methyl chloride & Chlorine feed line.

� Reactor dump tank is available to dump the reactor. (Emergency dumping sequence in place)

� Two sets of Rupture disc & Safety valve, to take care of over pressurization, is available on

the Reactor.

� Individual three level of leak alarm is available on all 14 UV lamps. Auto tripping of individual

UV lamp & whole plant on 2nd & 3rd leak alarm respectively.





Mitigation Measures



Operation JE

2. Technical controllers visit the site & assess whether to declare On Site Emergency or not.



4. Shut off UV lamps & dump the Reactor into dump tank. Control room JE

5. Complete the dumping sequence till reactor pressure is Zero. Control room & Field JE

6. Start water spray from water monitors & fire water hose to absorb the vapors in the environment. Don't spray water directly on the

Reactor.


7. Evacuate the area. Technical coordinator

SCENARIO 7: Hydro Chlorination Reactor leak

Control Measures

� Methyl chloride leak detector installed all around the reactor to detect ppm of leak.

� 2 nos. SCBA set kept in CMS control room.

� Reaction stoppage on high pressure of the Reactor.

� Reaction stoppage on high pressure of the Methanol line.

� Reactor dump tank is available to dump the reactor. (Emergency dumping sequence in place)

� Rupture disc & Safety valve, to take care of over pressurization, is available on the Reactor.

Mitigation Measures

S.

No.

Activity Responsibility


Operation JE

2. Technical controller visit the site & assess whether to declare On Site Emergency or not.



4. Stop the plant & de-gass the reactor into dump tank & to HCl

scrubber to Zero pressure.

Operation JE

5. Start reactor cooling & when temperature is < 90oC, dump the reactor into dump tank using transferring pump.

Operation JE

4. Ensure spillage, if any, in ISBL only. Operation JE

5. Start water spray from water monitors & fire water hose to absorb the vapors in the environment. Don't spray water directly

on the Reactor.


6. Evacuate the area. Technical coordinator





SCENARIO 8: Fire in Methyl Chloride storage Tank

Control Measures

� 12 nos. Methyl chloride leak detector installed in CMS plant area.

� Reaction stoppage on high pressure of the storage tanks.

� Reaction stoppage on high level of the storage tanks.

� Two sets of Rupture disc & Safety valve, to take care of over pressurization, is available on

each tank.

� Rupture disc vent connected with Faraday Cage for safe discharge.

� Dyke wall available.

Mitigation Measures


1 Inspect the area, assess the magnitude of fire & inform to Technical controller & Control room.

Operation JE

2 Use portable fire extinguisher to put off the fire immediately. Technical

Coordinator to be informed & declare On Site emergency.

Technical Controller/ JE

Operations

3 Isolate the storage tank from all other processes. Technical Controller/ JE

Operations

4 Start Fire pump. Security staff

5 Start the water spray to extinguish the fire. Security Guard/ Fire staff

6 Evacuate the area. Tech Coordinator

7 Cool the adjacent area by spraying water. Security staff

SCENARIO 9: Fire in Methanol storage tank

Control Measures


� Medium Velocity water spray system installed around Methanol tanks.

� Breather vent with flame arrestor provided in Methanol tanks.

� Overflow line provided. In Methanol tanks overflow line with water seal provided.

� Foam pouring system provided.

Mitigation Measures


1 Inform Control Room. Field Operator/ Field JE

2 Technical Coordinator to be informed & declare On Site emergency. Control room JE


4 Ensure that Medium Velocity spray system has been operated

automatically, if not then start manually.

Field JE

5 Open valve of foam pourer & start foam pouring. Field JE

6 Start water spray from water monitors & fire water hose. Security staff

7 Also keep the adjacent tank cool by water spray over these. Security staff

8 If fire is still uncontrolled call the external help & ask them to bring

foam tender/ extra amount of foam.

Technical Coordinator

9 Evacuate the area. Technical coordinator





SCENARIO 10: Fire in HSD/ LSHS storage tank

Control Measures


� Overflow line provided. In Methanol tanks overflow line with water seal provided

� Foam pouring system provided in one HSD tank

Mitigation Measures


1 Inform HOD Utility & Technical Coordinator & Security Field Operator/ Utility JE

2 Technical Coordinator assess the emergency & declare On Site

emergency.

CMS Control room JE

Inform CMS control room to sound the emergency hooter Technical Coordinator


4 Ensure that Medium Velocity spray system has been operated

automatically, if not then start manually.

Utility JE/ Technician

5 Open valve of foam pourer & start foam pouring in HSD tanks Utility JE


7 Also keep the adjacent tank cool by water spray over these. Security staff

8 If fire is still uncontrolled call the external help & ask them to bring

foam tender/ extra amount of foam.



SCENARIO 11: Fire in Methanol tanker during Unloading

Control Measures

� Earthing of tankers as soon as tanker reach the destination to dissipate static charge.

Mitigation Measures


1 If fire is small immediately put off the fire with the help of Foam/

ABC/DCP/CO2 fire extinguisher. Inform Control Room.

Field Operator



5 Ensure that Medium Velocity spray system has been operated automatically, if not then start manually.

JE

6 If possible isolate the downstream system. JE/ Field operator

7 Spray water from Monitors & fire hoses to keep tanker cool. Security staff

8 Pour foam over the fire. Security staff


10 Spray water on other tank in the vicinity to keep these cool. Security staff/ fire fighting

staff

SCENARIO 12: CMS Storage Tank failure

Control Measures



� Wind Sock provided to know the wind direction.





Mitigation Measures



Filling operator




4 Ensure that Dyke valve is in close position. JE Operations



7 Remove all vehicles in the area. Tech Coord./ JE Operations


9 Spray firewater from hoses over the vapors to knock down the

same.


10 Transfer CMS to the empty tank by transfer pumps to the extent possible. Also, fill CMS tankers, if available, by loading pumps.

JE Operations

11 Absorb the remaining CMS in sand or saw dust & wash the area with water.

JE Operations

SCENARIO 13: Fire in Coal/Husk storage

Control Measures

� Fire hydrant system with monitors provided around Coal storage.

� Area remained manned round the clock

� Trained fire fighting team is available.

Mitigation Measures


1 Inform Operationofficer/ Technical Coordinator & Security Field Operator/ JE


emergency.Simultaneoulsy following mitigation activities shall be started immediately.

Tech Coordinator

3 Inform Main Gate Security Incharge to sound the emergency hooter Technical

Coordinator


5 Ask operation officer to get ready for plant stoppage Technical coordinator

6 Start water spray from water monitors & fire water hose. Emergency Team

7 Flood the water over fire zone Emergency team

8 If fire is still uncontrolled call the external help & ask them to bring fire tender/

extra amount water

Emergency Team

9 If required Evacuate the area. Technical

Coordinator





SCENARIO 14: Fire in Hydrogen Trolla

Control Measures

� Fire Hydrant System provided.

� CCTV for monitoring.

� Physical monitoring

Mitigation Measures


1 Inform Operationofficer/ Technical Coordinator & Security Field Operator/ JE


emergency.Simultaneoulsy following mitigation activities shall be started immediately.

Tech Coordinator

3 Inform RG-HF Control to sound the emergency hooter Technical Coordinator


5 Arrange for removal of 2nd Trolla (if any), away from the hydrogen shed Technical coordinator

6 Ask operation officer to stop the plant Technical coordinator

7 Start water spray from water monitors & fire water hose. Emergency Team

8 Cordonn off the area to stop the entry Emergency team

9 If fire is still uncontrolled call the external help & ask them to bring fire tender/

extra amount water

Emergency Team

10 If required Evacuate the area. Technical

Coordinator

11 If situation gets under controll askControl Room to blow the All clear Siren. Technical

Coordinator

SCENARIO 15: Fire in Methanol, Toluene or Fluorobenzene storage tank

Control Measures

� Breather vent with flame arrestor provided in al flammable material tanks.

� Fire Extinguishers installed.

� Fire hydrant system installed around the plant.

� Flame sensor provided.

Mitigation Measures




3 If fire is small use portable fire extinguishersb to extinguish the fire. Field Operator/ Field JE



6 Also keep the adjacent tank cool by water spray over these. Security staff/JEs

7 If fire is still uncontrolled call the external help & ask them to bring foam

tender/ extra amount of foam.







SCENARIO 16: Br2 vessel failure

Control Measures

� Operation is under vacuum.

� Br2 sensor installed.

� Cover all chemicals suit & SCBA provided in the Control Room

Mitigation Measures



JE Operations




4 Wear all cover suit & SCBA. JE Operations



7 Spray firewater from hoses over the fumes to control and contain acid

fumes from spreading. Water should not be sprayed directly over liquid pool.


8 Dump the material into the reactor. JE Operations

9 Neutralize the residual, if any, with Sodium Thio Sulphate solution or lime . Wash the slurry with water to dyke pit and pump to ETP.

JE Operations


SCENARIO 17: TFA Storage Tank failure

Control Measures

� CAS provided

� Fire hydrant around the plant provided.


Mitigation Measures


1 Inspect the area, assess the leak & inform to Technical controller &

Control room.

JE Operations

2 Technical controller visit the site & assess whether to declare On

Site Emergency or not.


Operations


4 Wear the all cover suit & SCBA. JE Operations



7 Spray firewater from hoses over the fumes to control and contain acid fumes from spreading. Water should not be sprayed directly

over liquid pool.


8 Neutralize the residual acid, if any, with lime powder. Wash the slurry with water and pump to ETP.

JE Operations

9 For situation beyond control, shut down the plant & evacuate the area.






SCENARIO 18: BN/PFBN leakage from fluorination reactor

Control Measures

� Safety valve provided.

� Emergency release valve provided


� Fire extinguishers provided on the floors.

� Flame sensor provided.

Mitigation Measures


1 Inspect the area, assess the leak & inform to Technical controller &

Control room.

JE Operations

2 Technical controller visits the site & assess whether to declare On Site

Emergency or not.


Operations

3 Ensure that there is no ignition source is available in the plant area. Technical Controller/ JE Operations





8 Spray firewater from hoses over the fumes to control and contain BN/

PFBN fumes from spreading. Water should not be sprayed directly over leaky point.

Security staff/ Operation

JE


SCENARIO 19: Fire in HOG drain/Dump tanks

Control

� Flame arrester available on the drain tanks.

� AFFF Extinguisher and DCP type extinguishers available.

� Hydrant system With Water monitor available


Mitigation Measures


1 Inspect the area, assess the magnitude of fire & inform to Technical co-ordinator & Control room.Simultaneoulsy following mitigation activities shall

be started immediately.

Operation JE

2 Use portable fire extinguisher to put off the fire immediately. Technical

Coordinator to be informed & declare On Site emergency.

Technical Controller/

JE Operations

3 Isolate the storage tank from all other processes. Technical Controller/ JE Operations

4 Start Fire hydrant pump. Security staff / RG Utility

5 Start the water spray to extinguish the fire.Use the Water Monitor nearby to cool adjacent tanks.

Security Guard/ Fire staff





6 Use foam monitor to pour the foam on the fire Operation People/ Fire staff

7 Mechanical foam trolley may also be used to pour the foam on fire Operation People/ Fire staff

8 Evacuate the area. Tech Coordinator

9 Cool the adjacent area by spraying water. Security staff

SCENARIO 20: Ammonia leak in compressor area

Control Measures

� 1nos. SCBA set kept at compressor area.

� Water monitor around compressor area.

� Rupture disc & safety valve provided.

� Temperature indicator & alarm in DCS System.

� Pressure indication & alarm in DCS system.

Mitigation Measures



Utility area operator

2 Technical controller visit the site & assess whether to declare On Site Emergency or not. Simultaneoulsy following mitigation activities shall be

started immediately.

Technical Controller/ JE Utility

3 Start Fire hydrant pump. Security staff / RG Utility

4 Wear SCBA set. Utility area operator

5 Start sprinkler system, water Monitor & Hydrant system Utility area operator

6 Isolate the electrical supply & start the Water spray system JE (Utility)

7 Evacuate the area. Technical Controller/ JE Utility

8 Take the help of other person came from control room. Process JE

9 Arrest the leak with the help of Process personel Utility area operator

10 Restrict the area for non essential persons Tech. Coordinator

11 Ensure Use of Air line / SCBA breathing system for the personnel attending the leak.

Technical Controller/ JE Utility

12 Check the Ammonia concentration in the surrounding area JE/ Environment officer

SCENARIO 21: Fire in P61, Ethanol tanker during Unloading

Control Measures

� Earthing of tankers before unloading

� Earthing and bonding of tanks

� Fixed Foam System are provided at MTF

� Mobile foam trolley is available






1 If fire is small immediately put off the fire with the help of Foam/ ABC/DCP/CO2

fire extinguisher. Inform Control Room.

Field Operator



4 If possible isolate the downstream system. JE/ Field operator

5 Spray water from Monitors & fire hoses to keep tanker cool. Security staff

6 Pour foam over the fire. Security staff

7 Evacuate the area. Technical

coordinator

8 Spray water on other tank in the vicinity to keep these cool. Security staff/ fire fighting staff

SCENARIO 22: Fire in Ethanol storage tank

Control Measures

� Earthing of tankers before unloading

� Earthing and bonding of tanks

� Fixed Foam System are provided at MTF

� Mobile foam trolley is available

Mitigation Measures




3 If fire is small use portable fire extinguishersb to extinguish the fire. Field Operator/ Field JE



6 Also keep the adjacent tank cool by water spray over these. Security staff/JEs

7 If fire is still uncontrolled call the external help & ask them to bring foam tender/ extra amount of foam.



SCENARIO 23: P8/P9 Storage Tank failure

Control Measures


� Fire hydrant system installed around the plant.

� Dyke wall is available





Mitigation Measures



JE Operations

2 Technical controller visits the site & assesses whether to declare On Site Emergency or not.



4 Wear the all cover suit & SCBA. JE Operations



7 Spray firewater from hoses over the fumes to control and contain acid fumes

from spreading. Water should not be sprayed directly over liquid pool.

Security staff/

Operation JE

8 Neutralize the residual acid , if any, with lime powder. Wash the slurry with

water and pump to ETP.

JE Operations


SCENARIO 24 : Ammonia leakage From cylinder

Control Measures

� SCBA set kept at Control Room.

� Water curtain is available

� Water monitor and hydrant point are available

� Emergency Kit is Available

Mitigation Measures



JE Operations

2 Technical controller visits the site & assesses whether to declare On

Site Emergency or not.


Operations


4 Wear SCBA set. JE Operations

5 Start water Curtain

6 Arrest the leak with the help of emergency kit JE Operation

7 Isolate the electrical supply & start the Water spray system Tech Coord.


9 Restrict the area for non essential persons Tech. Coordinator

10 Ensure Use of SCBA breathing system for the personnel attending the leak.

Technical Controller

11 Check the Ammonia concentration in the surrounding area JE/ Environment officer

SCENARIO 25: Fire in R&D

Control Measures


� Fire hydrant system installed near to R&D centre

� Mobile foam trolley in P6 plant





Mitigation Measures

S. No.

Activity Responsibility

1 If fire is small use portable fire extinguishers to

extinguish the fire.

Chemist/operator

2 Inform Technical Coordinator & Security Chemist/Operator.


4 Start water spray/Foam from fire water hose. Security staff /ERT member on instruction of technical cordinator

5 Close the supply of Hydrogen Chemist/Operator

6 Remove all Cylinder from R&D Technical coordinator

7 If required Evacuate the area. Technical coordinator

SCENARIO 26: Fire in Product shed-SCB

Control Measures


� Fire hydrant system installed


Mitigation Measures


1 If fire is small use portable fire extinguishers to extinguish the fire. Operator

2 Inform Technical Coordinator & Security JE Process


4 Start water/foam spray from fire water hose. Security staff /ERT member on instruction of

technical coordinator

5 Also keep the adjacent tank cool by water spray over these. Technical coordinator

4 If fire is still uncontrolled call the external help & ask them to bring foam

tender/ extra amount of foam.

Technical coordinator


SCENARIO 27 : Spillage of Br2 due to brakage of bottle-SCB

Control Measures

� SCBA and cover all suit is available

� Lime and Sodium thio sulphate soultion is kept in plant





Mitigation Measures



Operator

2 Technical controller visit the site& assess the leak Technical coordinator

3 Wear SCBA and PVC suit JE Process

4 Put lime on the spillage bromine Security staff /ERT member on instruction of technical cordinator

5 Spary the Sodium thio sulphate solution on the Br2 liquid Technical coordinator


SCENARIO 28: Fire in chemical Yard-SCB

Control Measures


� Fire hydrant system installed.


Mitigation Measures


1 If fire is small use portable fire extinguishers to extinguish the fire. Operator

2 Inform Technical Coordinator & Security JE Process


4 Start water/foam spray from fire water hose. Security staff /ERT member on instruction of technical cordinator

5 Also keep the adjacent drum cool by water spray over these. Technical coordinator

6 Remove other drums if possible. Technical coordinator

7 If fire is still uncontrolled call the external help & ask them to

bring foam tender/ extra amount of foam.

Technical coordinator


SCENARIO 29: Radiation from nucleonic gauge

Control Measures

� All sources kept in lead boxes.

� Fencing provide around the nucleonic sources

� Warning sign displayed near the all nucleonic sources.

� Periodic radiation checking around the nucleonic sources in ON & OFF condition with

Radiation Survey Meter.

� Trained manpower- BARC certified radiation officer (RSO)





Mitigation Measures


1 If the radiation observed is higher than the specified limit of 2mR/Hr in periphery on 1 meter. The individual source shall be covered in another lead

box.

RSO

2 If the ambient radiation level observed is higher than the 0.25 mSv/h at 100

meter from the facility:

2.1 Declare on site emergency as per procedure defined in SRF genenrnal emergency response plan.

RSO/ Shift in-charge

2.2 SRF site have four assembly points to assemble at safe points during emergency. The same assemble points will be used in case of ambient radiation

from the nucleonic sources used in SRF site, Bhiwadi.

All employees & contract workers

2.2 Inform BARC official for further course of action and guidance. Admn Co-ordinator

(HOW) / RSO

3 In the event that a site emergency situation deteriorates into off site emergency:

3.1 Inform to local as well as district emergency authorities Admn Co-ordinator (HOW) / RSO

3.2 Evacuate the area. Chief / admn Co-ordinator

3.3 Inform BARC official for further course of action and guidance. Admn Co-ordinator

(HOW) / RSO

7.2.5.8 Mock Drill for Emergency

� Head (EHS) fixes-up the date and area of Mock Drill in consultation with Head (TS & EHS) and

Head of Works on the day of the Mock Drill. The time of drill may or may not be fixed before

hand in order to check the emergency preparedness of the plant.

� The Mock Drill for chemical leakage and fire is carried out at least quarterly as per the Onsite

Emergency / Disaster Control plan.

� Head (EHS) deputes observers chosen from Plants & EHS deptt. to observe the activities at

the site of Mock incident, ECC & Incident Control Room and note down the violations

occuring during the exercise.

� After finishing the Mock drill a meeting is being held with Head of Works to share the

findings & area of improvement. The meeting is attended by observers and all other

responsible person involved in the drill.

� Head (EHS) prepares Mock Drill report as per Format 4.4.7_F-02 stating the sequence of

events with timings, the deviations /violations, the reasons, necessary actions for compliance

with /improvement upon the Plan, Process Heads responsible.

� Head (EHS) circulates the Mock Drill Report copy to Head of Works & all Process Heads

responsible for Mock Drill Plan compliance within three working days.

� Head (EHS) monitors and presents the status of improvement actions, based on last Mock

Drill, in the next statutory safety committee meeting. The actions to be taken further are

recorded in statutory safety committee MOM.





� Onsite Emergency Plan is updated, if necessary, based on the findings of Mock Drill.

Updation of On-site Emergency Plan is authorised by CEO with adequate justifications.

� After updation, all the employees, especially the key persons as per On-site Emergency Plan,

are informed and/or trained suitably, if required, before the next Mock Drill.

7.2.5.8.1 Priority list of Scenario for conducting Mock Drill

S. No. Scenario Frequency

1 Chlorine Leak from Tonner valve/ body leak Tonner unloading tube leak Once in a Year

2 HF Leakage Tank Failure Pipeline Failure Once in a Year

3 HCL/Sulphuric/Oleum Leakage Tank Failure Pipeline Failure Once In a Year

4 Fire In Methanol Tank/ Ethanol Tank C1 Storage Tank HSD/LSHS Tank

Hydrogen Trolla Coal Yard /Husk Yard HOG

Once in a year

7.2.5.8.2 Procedure of Mock Drill

Responsibiliity of Conducting Mock Drill EHS

Information to be given Surprise drill, to be only pre-intimated to HOW & AVP ( EHS) &

Concerned Plant Head

Observers Observers are to selected from EHS team & other Plant officers.

Roll Call To be taken by Administration & communicated to EHS

Post critique meeting Post critique meeting to be conducted involving HOW, observers, & all concerned officers involved in Emergency mock drill)

Minutes of Meeting To be drafted & circulated by EHS

Follow up of corrective actions for deviations emerged during Mock Drill

Once in a 15 days by EHS

7.2.5.9 Chlorine Emergency Kit

Chlorine kits are available in Chlorine area, RG plant, Cooling Tower RG/HF, FSP ( P3) Chlorine Feed

Area & CPP cooling Tower area.

A Chlorine kit consists of following items:

TABLE 7.9

Details of Chlorine Kit

S. No. Item Quantity

1 Big Hood with VENT valve 1

2 Rubber Gasket(OD155mm-ID 90 mm ) 3

3 Tie Rod Assembly 1

Tie Rods 2

Tie Rods Washers 8

Tie Rod Pipe Pieces 4

Angle 2

Stud with Welded Handle 1

4 Small Hood 1

5 Yoke 1





6 Studs 1

7 Rubber Gasket(OD115mm-ID 60 mm) 3

8 Blind fiber Gasket (1" O ) 3

9 Fiber Gasket (!.25" OD - 0.75 ID ) 3

10 Cap Nut 1

11 Steel Patch Plate 1

12 Rubber Gasket (80 mm square) 2

13 Round Yoke Plate 1

14 Cap Screw 1

15 Chain (96"long) 2

16 Drift Pins (In Two Sizes) 2

17 Hammer 1

18 Valve Cap 1

19 Yoke Clamp 1

20 Flexible Copper Tubing 1

21 Teflon Tape 1

22 Ammonia Torch 1

23 Ammonia Solution Bottle 1

24 Valve Spindle (10 mm Square) 1

25 Spanner-30 # 32 mm 1

26 Spanner-3/4" # 5/8" 1

27 Blind fiber Gasket (20 mm O ) 3

7.2.5.10 Evacutation Procedure

"The Maximum credible loss scenario in Chemicals Business is rupture of Chlorine Tonner. As per

QRA result in case of catstrophic rupture of Chlorine Tonner 3273 square meter area will get

affected in IDLH range within 87.52 Seconds. The Chlorine will travel in specific direction depending

upon the wind direction. Looking into size of the site i.e. approx 84 acres, still lot of open area

remains unaffected. Follwing action would be required for the evacuation:

After declaring the emergency, Incident controller should arrange for announcement of wind

direction and safer Assembly points. In case of extreme emergency, decision would be taken for

evacuation of plant people, who have assembled at the assembly point, by Chief Co-ordinator. The

assembled person will be required to be evacuated in safer direction within the Plant premises."

"Depending on prevailing wind direction and place of emergency, there is a pedestrian road leading

to outside the factory premises from four gates provided in different directions of the factory,

through which the people would be evacuated to safer locations in nearby villages.

Following procedure will be followed by Security person posted on gate duty for safe evacuation.

As soon as Emergency Hooter is sounded Security person manning the gates should come to the

gate & unlock the same. The gate should be kept in closed condition. This instruction shall be

displayed near the gates.





All Security person manning these gates shall be equipped with Walkie-Talkie. In case of evacuation

is needed and any of these require to be opened, instruction shall be given from ECC/ Security main

gate to security person on gate duty to open the gate for evacuation.

The affected people will be evacuated with the help of Ambulance & Jeep available round the clock

within the premises.

"The outside community people shall be communicated using Public address system. For this

purpose a Company Jeep equipped with Public Announcement system will go to nearby villagers

and inform them about the emergency and safe route of evacuation. Security Incharge will be

responsible for this activity. In addition to this help would be taken from local administration for

information & evacuation of the nearby villagers if required.

Administration Coordinator will be responsible for arrangement of the vehicle to evacuate nearby

villagers falling in the wind direction. For this purpose he will take help of Local Administration.

External environment shall be protected by using copius amount of water spray around emergency

area to subside the spreading of the vapors. "

Above evacuation procedure shall be applicable for all three shifts.

7.2.5.11 Medical facility

A 24 hours manned Medical centre is available in the factory to provide First Aid treatment to the

Employees & Contract workers.

A full time Medical Doctor is available on 10 minutes call.

Trained and experienced Medical Male Nurse round the clock.

Other facility available in Medical Centre:-

S. No. ITEM Availability Remarks

1 Rooms 3 nos. Air Conditioned Room

2 Bed 3 Nos. Each bed equipped with oxygen Set

3 Oxygen Set 3 nos.

4 Spare Oxygen Cylinders 1 no.

5 Medicines/ Antidotes As per

requirement

Medicine / Antidote are available for all chemicals.

6 Nebuliser 2 Nos.

7 Stretcher 2 Nos.

8 Ambulance Van 1 No. Ambulance van is equipped with Stretcher,

Oxygen Set & PPE's kit.





LIST OF FIRST-AID BOXES INSIDE THE FACTORY:

S. No. Location Item

1 RG/HF Control room BANDAGE, COTTON, SAVALON, BETADINE OINTMENT, SEISER,OINTMENT for external use, BAND AID 2 CMS Control room

3 Chlorine area

4 RG Filling Station

5 Electrical Substation

6 JE (Utility) room

7 Store

8 CPP Control Room

9 HFC-134a Control Room

10 SCB P2 Control Room



12 SCB P2 Filling area

13 SCB P6 Filling area

7.2.6 Off Site Emergency

In case of Off-Site Emergency, prime responsibility lies with the local administration for

communication to nearby area, evacuation, providing emergency services like transportation,

rescue team, medical help etc. District Collector/ Additional District Collector becomes Chief

Controller for Off-site emergency

SRF's responsibility in case of Off-site Emergency

SRF will initiate all possible measures to control the emergency within the premises without

affecting the outside area. Despite this if situation arises & emergency becomes off site following

action shall be taken to minimize the damage to outside people & environment.

S.

No.

Item Responsibility Action Remarks

1 Communication to

officials about emergency

Administrative

Coordinator

Administrative coordinator will take

consent of Chief Coordinator to inform about emergency to following '-District Magistrate/ Additional DM/SDM

-SP/DYSP -Factory Inspectorate

-Fire Brigade

-Neighbour Industries

-Sarpanch of nearby villagers

Contact Nos. are

available in External telephone list

2 Communication to nearby community

Administrative Coordinator

Administrative coordinator will ask Fire/Rescue officer to send the jeep

equipped with Public address system for making announcement about emergency

& safe evacuation in nearby villages.

Round the clock Presence of One

jeep is to be ensured.

3 Communication to media/ villagers

about situation of

Administrative Coordinator

Administrative coordinator will interact with media/ villagers to update them

about situation.





S. No.

Item Responsibility Action Remarks

emergency

4 Traffic Control Security Officer Security officer will instruct the Security

staff and guard officer on duty to mobilise the vehicle to safer area & keep personal gate free from any obstacle for

evacuation/entry of fire tender etc.

Wind direction is

to be considered to decide the safer entry/ exit

gate.

5 Arrangement of

transportation for evacuation

Administrative

Coordinator

Administrative coordinator will arrange

the transportation for evacuation of person inside the premises & also people residing in the near vicinity. This will be in

addition to assistance provided by local authorities.

6 Medical Help Medical Officer/ Liaison Officer

Medical officer will assist liaison officer to contact the Hospitals & shifting of

injured.

7 Emergency Mitigation

Chief Controller Chief Coordinator will remain in touch with Technical coordinator & safety

Coordinator for early mitigation of the emergency, he will also get in touch with

emergency expert team from Local crisis group/District Crisis group.

List of Emergency crisis group will

be made available after its

formation.

8 Declaration of All

clear

DM/SDM/ Chief

Coordinator

After controlling the emergency Chief

coordinator will take consent from DM/SDM to declare All clear for Offsite

emergency.

9 Comm. About All

clear

Administrative

Coordinator

Administrative coordinator will ask

Security officer to announce all clear in the near vicinity.

7.2.7 Conclusion

It has concluded that there will be no major risk involved due to proposed expansion plant. Proper

precaution will be taken so risk can be minimized. Personal Protective Equipments (PPEs) will help

to minimize the health hazards and accidental casualties. So it is safe to say that there will be no

major risk involved due to the proposed expansion plant.

7.2 risk assessment and disaster management plan...

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